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KOMATSU 930E-4 DUMP TRUCK Shop Manual – PDF DOWNLOAD
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Description
KOMATSU 930E-4 DUMP TRUCK Shop Manual
FILE DETAILS:
KOMATSU 930E-4 DUMP TRUCK Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM028100
Total Pages : 1356
DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK Shop Manual
FOREWORD:
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information.
- The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
- All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual.
- Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E).
- The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK Shop Manual
FOREWORD........................................................................................................................................................................................ 5 TABLE OF CONTENTS............................................................................................................................................................................... 7 SECTION A GENERAL INFORMATION INDEX............................................................................................................................................................. 9 COMPONENTS & SPECIFICATIONS..................................................................................................................................................................... 11 MAJOR COMPONENT DESCRIPTIONS................................................................................................................................................................ 11 Truck And Engine........................................................................................................................................................................ 11 Main Alternator......................................................................................................................................................................... 11 AC Induction Traction Motorized Wheels.................................................................................................................................................. 11 Suspension.............................................................................................................................................................................. 11 Operator's Cab.......................................................................................................................................................................... 11 Power Steering.......................................................................................................................................................................... 11 Dynamic Retarding....................................................................................................................................................................... 11 Brake System............................................................................................................................................................................ 11 SPECIFICATIONS.............................................................................................................................................................................. 13 ENGINE.................................................................................................................................................................................. 13 AC ELECTRIC DRIVE SYSTEM................................................................................................................................................................ 13 DYNAMIC RETARDING....................................................................................................................................................................... 13 BATTERY ELECTRIC SYSTEM................................................................................................................................................................. 13 SERVICE CAPACITIES...................................................................................................................................................................... 13 HYDRAULIC SYSTEMS....................................................................................................................................................................... 14 SERVICE BRAKES.......................................................................................................................................................................... 14 STEERING................................................................................................................................................................................ 14 TIRES................................................................................................................................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS............................................................................................................................................ 14 WEIGHT DISTRIBUTION..................................................................................................................................................................... 15 SAFETY.......................................................................................................................................................................................... 17 GENERAL..................................................................................................................................................................................... 17 Safety Rules............................................................................................................................................................................ 17 Safety Features......................................................................................................................................................................... 17 Fire Extinguisher And First Aid Kit..................................................................................................................................................... 17 Clothing And Personal Items............................................................................................................................................................. 17 Leaving The Operator’s Seat............................................................................................................................................................. 18 Mounting And Dismounting................................................................................................................................................................ 18 Fire Prevention For Fuel And Oil........................................................................................................................................................ 18 Precautions With High Temperature Fluids................................................................................................................................................ 19 Asbestos Dust Hazard Prevention......................................................................................................................................................... 19 Prevention Of Injury By Work Equipment.................................................................................................................................................. 19 Unauthorized Modification............................................................................................................................................................... 19 Precautions When Using ROPS............................................................................................................................................................. 19 Precautions For Attachments............................................................................................................................................................. 20 Precautions For Starting The Truck...................................................................................................................................................... 20 PRECAUTIONS BEFORE OPERATION................................................................................................................................................................ 20 Safety At The Worksite.................................................................................................................................................................. 20 Fire Prevention......................................................................................................................................................................... 21 Ventilation In Enclosed Areas........................................................................................................................................................... 21 Preparing For Operation................................................................................................................................................................. 21 Mirrors, Windows And Lights............................................................................................................................................................. 21 In The Operator Cab (Before Starting The Engine)........................................................................................................................................ 21 Seat Belts.............................................................................................................................................................................. 21 OPERATING THE TRUCK......................................................................................................................................................................... 22 When Starting The Engine................................................................................................................................................................ 22 General Truck Operation................................................................................................................................................................. 22 Ensuring Good Visibility................................................................................................................................................................ 22 Traveling............................................................................................................................................................................... 23 Traveling In Reverse.................................................................................................................................................................... 23 Traveling On Slopes..................................................................................................................................................................... 23 Operating On Snow Or Ice................................................................................................................................................................ 23 Avoid Damage To Dump Body............................................................................................................................................................... 23 Driving Near High Voltage Cables........................................................................................................................................................ 24 Working On Loose Ground................................................................................................................................................................. 24 When Dumping............................................................................................................................................................................ 24 When Loading............................................................................................................................................................................ 24 Parking The Truck....................................................................................................................................................................... 24 Towing.................................................................................................................................................................................. 24 WORKING NEAR BATTERIES...................................................................................................................................................................... 25 Battery Hazard Prevention............................................................................................................................................................... 25 Jump Starting With Booster Cables....................................................................................................................................................... 26 Jump Starting With Receptacles.......................................................................................................................................................... 26 BEFORE PERFORMING MAINTENANCE............................................................................................................................................................... 27 Stopping The Engine Before Service...................................................................................................................................................... 27 Electrical Systems Isolation............................................................................................................................................................ 27 Warning Tag............................................................................................................................................................................. 29 Proper Tools............................................................................................................................................................................ 29 Use of Tie-Off Anchor During Maintenance and Repair..................................................................................................................................... 29 Securing The Dump Body.................................................................................................................................................................. 29 WHILE PERFORMING MAINTENANCE................................................................................................................................................................ 30 Keep The Truck Clean.................................................................................................................................................................... 30 Attachments............................................................................................................................................................................. 30 Working Under The Truck................................................................................................................................................................. 30 Rotating Fan And Belts.................................................................................................................................................................. 30 Waste Materials......................................................................................................................................................................... 30 Adding Fuel Or Oil...................................................................................................................................................................... 31 Radiator Coolant Level.................................................................................................................................................................. 31 Use Of Lighting......................................................................................................................................................................... 31 Precautions With The Battery............................................................................................................................................................ 31 Handling High Pressure Hoses............................................................................................................................................................ 31 Precautions With High Pressure Oil...................................................................................................................................................... 31 Performing Maintenance Near High Temperature Or High Pressure........................................................................................................................... 31 TIRES....................................................................................................................................................................................... 32 Handling Tires.......................................................................................................................................................................... 32 Tire Maintenance........................................................................................................................................................................ 32 Storing Tires After Removal............................................................................................................................................................. 32 ADDITIONAL JOB SITE RULES....................................................................................................................................................................... 33 WHEN REPAIRS ARE NECESSARY.................................................................................................................................................................. 34 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.......................................................................................................................................... 35 Preliminary Procedures Before Welding or Performing Maintenance......................................................................................................................... 35 Engine Shutdown Procedure Before Welding or Performing Maintenance...................................................................................................................... 35 CAPACITOR DISCHARGE SYSTEM.................................................................................................................................................................. 37 Necessary Tools......................................................................................................................................................................... 37 Warnings And Cautions................................................................................................................................................................... 38 Manual DC Link Capacitor Discharge Procedure............................................................................................................................................ 39 Failure of the Discharge System......................................................................................................................................................... 41 Manual Discharge of Capacitors.......................................................................................................................................................... 42 Short Isolated Capacitor Terminals...................................................................................................................................................... 44 OPERATING INSTRUCTIONS.......................................................................................................................................................................... 45 PREPARING FOR OPERATION..................................................................................................................................................................... 45 WALK AROUND INSPECTION...................................................................................................................................................................... 45 RETRACTABLE LADDER SYSTEM (Optional)........................................................................................................................................................ 49 Description............................................................................................................................................................................. 49 Normal Operation........................................................................................................................................................................ 49 General Safety.......................................................................................................................................................................... 49 IN-CAB CONTROL PANEL........................................................................................................................................................................ 50 Digital Display Screen.................................................................................................................................................................. 50 Command Buttons......................................................................................................................................................................... 50 USING THE IN-CAB CONTROL PANEL.............................................................................................................................................................. 51 Raising the Ladder...................................................................................................................................................................... 52 Lowering the Ladder..................................................................................................................................................................... 52 USING THE GROUND LEVEL CONTROL BOX.......................................................................................................................................................... 53 Raising the Ladder...................................................................................................................................................................... 53 Lowering the Ladder..................................................................................................................................................................... 53 EMERGENCY OPERATION......................................................................................................................................................................... 54 ENGINE START-UP............................................................................................................................................................................. 55 AFTER ENGINE HAS STARTED.................................................................................................................................................................... 56 PRE-SHIFT BRAKE CHECK....................................................................................................................................................................... 57 Events.................................................................................................................................................................................. 57 OPERATION................................................................................................................................................................................... 57 Description............................................................................................................................................................................. 57 Brake Test Exit Criteria................................................................................................................................................................ 58 PERFORMING THE BRAKE TESTS.................................................................................................................................................................. 59 Setup................................................................................................................................................................................... 59 Service Brake Test...................................................................................................................................................................... 59 Parking Brake Test...................................................................................................................................................................... 60 Retard System Test...................................................................................................................................................................... 61 EMERGENCY STEERING SYSTEM................................................................................................................................................................... 61 Operation............................................................................................................................................................................... 61 Pre-Operation Testing................................................................................................................................................................... 61 Additional Guidelines................................................................................................................................................................... 62 MACHINE OPERATION SAFETY PRECAUTIONS........................................................................................................................................................ 62 OPERATING ON THE HAUL ROAD.................................................................................................................................................................. 63 STARTING ON A GRADE WITH A LOADED TRUCK..................................................................................................................................................... 64 PASSING..................................................................................................................................................................................... 64 LOADING..................................................................................................................................................................................... 64 Overload Speed Limit Function........................................................................................................................................................... 64 DUMPING..................................................................................................................................................................................... 65 Raising The Dump Body................................................................................................................................................................... 65 Lowering The Dump Body (When dumping on flat ground).................................................................................................................................... 66 Lowering The Dump Body (When dumping over a berm or into a crusher)..................................................................................................................... 66 SUDDEN LOSS OF ENGINE POWER................................................................................................................................................................. 67 If traffic is heavy near the disabled machine, mark the truck with warning flags during daylight hours or use flares at night. Adhere to local regulations.................................. 67 FUEL DEPLETION.............................................................................................................................................................................. 67 SAFE PARKING PROCEDURES..................................................................................................................................................................... 68 NORMAL ENGINE SHUTDOWN PROCEDURE............................................................................................................................................................ 68 Close and lock all windows. Remove the key from the key switch and lock the cab to prevent possible unauthorized truck operation. Properly dismount the truck. Put wheel chocks in place.... 69 DISABLED TRUCK DUMPING PROCEDURE............................................................................................................................................................ 70 Hookup.................................................................................................................................................................................. 70 Raising the Body........................................................................................................................................................................ 70 Lowering the Body....................................................................................................................................................................... 70 HOIST SYSTEM................................................................................................................................................................................ 71 Hookup.................................................................................................................................................................................. 71 Dumping Procedure....................................................................................................................................................................... 71 TOWING...................................................................................................................................................................................... 73 Special Wiring Harness.................................................................................................................................................................. 73 Towing Procedure........................................................................................................................................................................ 74 RESERVE ENGINE OIL SYSTEM (Optional)........................................................................................................................................................ 75 WARNINGS AND CAUTIONS........................................................................................................................................................................... 77 GRADE/SPEED CHART........................................................................................................................................................................... 77 KEY SWITCH.................................................................................................................................................................................. 77 ROPS/FOPS................................................................................................................................................................................... 77 BATTERIES................................................................................................................................................................................... 78 ISOLATION BOX............................................................................................................................................................................... 79 PROPEL LOCKOUT LEVER........................................................................................................................................................................ 79 CAPACITORS.................................................................................................................................................................................. 80 CRUSHING HAZARD............................................................................................................................................................................. 80 CYLINDER PRESSURE........................................................................................................................................................................... 81 FILLING THE HYDRAULIC TANK.................................................................................................................................................................. 81 HYDRAULIC OIL PRESSURE...................................................................................................................................................................... 82 HOT OIL SPRAY............................................................................................................................................................................... 82 WHEEL MOTOR OIL LEVEL....................................................................................................................................................................... 82 HOT EXHAUST................................................................................................................................................................................. 82 RADIATOR.................................................................................................................................................................................... 83 EMERGENCY LADDER............................................................................................................................................................................ 83 ACCUMULATOR DRAIN VALVES.................................................................................................................................................................... 83 EMERGENCY DUMP PROCEDURE.................................................................................................................................................................... 83 EMERGENCY TOWING PROCEDURE.................................................................................................................................................................. 83 WELDING..................................................................................................................................................................................... 84 EMERGENCY SHUTDOWN.......................................................................................................................................................................... 84 INFORMATION DISPLAY......................................................................................................................................................................... 84 WIRELESS SIGNALS............................................................................................................................................................................ 84 HIGH VOLTAGE................................................................................................................................................................................ 84 LIFTING INSTRUCTIONS........................................................................................................................................................................ 86 PRODUCT IDENTIFICATION PLATE................................................................................................................................................................ 87 LUBRICATION CHART........................................................................................................................................................................... 88 TORQUE TABLES AND CONVERSION CHARTS............................................................................................................................................................. 89 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values........................................................................................................................ 90 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts....................................................................................................................... 90 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws.......................................................................................................................... 91 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws...................................................................................................................................... 92 STORAGE AND IDLE MACHINE PREPARATION............................................................................................................................................................ 99 SHORT TERM IDLE PERIODS..................................................................................................................................................................... 99 PREPARATION FOR STORAGE..................................................................................................................................................................... 100 REMOVAL FROM STORAGE........................................................................................................................................................................ 101 RECONDITIONING AN IDLE VEHICLE.............................................................................................................................................................. 103 ENGINE OPERATION............................................................................................................................................................................ 105 After The Engine Has Started............................................................................................................................................................ 106 ENGINE STORAGE.............................................................................................................................................................................. 107 Temporary Storage (30 Days Or Less)..................................................................................................................................................... 107 Extended Storage (More Than 30 Days).................................................................................................................................................... 107 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................................................................................. 109 ELECTRIC DRIVE TRUCKS....................................................................................................................................................................... 110 Storing A Truck That Is Operational..................................................................................................................................................... 110 Storing A Truck That Is Not Operational................................................................................................................................................. 111 Storing A Major Component............................................................................................................................................................... 112 Periodic Inspections.................................................................................................................................................................... 112 Placing Equipment Into Service After Storage............................................................................................................................................ 112 SECTION B STRUCTURES INDEX...................................................................................................................................................................... 115 SECTION B2 STRUCTURAL COMPONENTS INDEX.......................................................................................................................................................... 117 STRUCTURAL COMPONENTS........................................................................................................................................................................... 119 PREPARATION................................................................................................................................................................................. 119 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................................................................................... 120 Removal................................................................................................................................................................................. 120 Installation............................................................................................................................................................................ 120 RH DECK AND RETARDING GRID.................................................................................................................................................................. 121 Removal................................................................................................................................................................................. 121 Installation............................................................................................................................................................................ 121 LH DECK..................................................................................................................................................................................... 122 Removal................................................................................................................................................................................. 122 Installation............................................................................................................................................................................ 122 CENTER DECK................................................................................................................................................................................. 123 Removal................................................................................................................................................................................. 123 Installation............................................................................................................................................................................ 123 SECTION B3 DUMP BODY INDEX...................................................................................................................................................................... 125 DUMP BODY....................................................................................................................................................................................... 127 DUMP BODY................................................................................................................................................................................... 127 Removal................................................................................................................................................................................. 127 Installation............................................................................................................................................................................ 128 BODY PADS................................................................................................................................................................................... 129 Body Pad Shimming Procedure............................................................................................................................................................. 130 BODY GUIDE.................................................................................................................................................................................. 130 HOIST LIMIT SWITCH.......................................................................................................................................................................... 131 BODY-UP SWITCH.............................................................................................................................................................................. 131 BODY RETENTION SLING........................................................................................................................................................................ 131 ROCK EJECTORS............................................................................................................................................................................... 132 Inspection.............................................................................................................................................................................. 132 SECTION B4 FUEL TANK INDEX...................................................................................................................................................................... 133 FUEL TANK....................................................................................................................................................................................... 135 Removal..................................................................................................................................................................................... 135 Installation................................................................................................................................................................................ 135 Repair...................................................................................................................................................................................... 137 Cleaning.................................................................................................................................................................................... 137 FUEL TANK BREATHER VALVE.................................................................................................................................................................... 137 Disassembly............................................................................................................................................................................. 137 Assembly................................................................................................................................................................................ 137 FUEL GAUGE SENDER (TOP)..................................................................................................................................................................... 138 Removal................................................................................................................................................................................. 138 Operation............................................................................................................................................................................... 139 Specifications:......................................................................................................................................................................... 139 QUICK FILL FUEL RECEIVERS (FRONT)........................................................................................................................................................... 140 SECTION C ENGINE INDEX.......................................................................................................................................................................... 141 SECTION C2 POWER MODULE INDEX................................................................................................................................................................... 143 POWER MODULE.................................................................................................................................................................................... 145 PREPARATION FOR REMOVAL..................................................................................................................................................................... 145 REMOVAL..................................................................................................................................................................................... 150 INSTALLATION................................................................................................................................................................................ 152 HOOKUP...................................................................................................................................................................................... 153 SECTION C3 COOLING SYSTEM INDEX................................................................................................................................................................. 155 COOLING SYSTEM.................................................................................................................................................................................. 157 RADIATOR.................................................................................................................................................................................... 157 Removal................................................................................................................................................................................. 157 Installation............................................................................................................................................................................ 159 Filling Procedure....................................................................................................................................................................... 160 REPAIRING THE RADIATOR...................................................................................................................................................................... 160 Internal Inspection..................................................................................................................................................................... 160 External Cleaning....................................................................................................................................................................... 160 Disassembly............................................................................................................................................................................. 161 Cleaning and Inspection................................................................................................................................................................. 162 Assembly................................................................................................................................................................................ 162 Pressure Testing........................................................................................................................................................................ 163 COOLANT SYSTEM TROUBLESHOOTING.............................................................................................................................................................. 163 SECTION C4 POWER TRAIN INDEX.................................................................................................................................................................... 165 POWER TRAIN..................................................................................................................................................................................... 167 ALTERNATOR REMOVAL.......................................................................................................................................................................... 167 ALTERNATOR INSTALLATION..................................................................................................................................................................... 169 Measuring Procedure..................................................................................................................................................................... 169 Joining the Alternator and Engine....................................................................................................................................................... 171 ENGINE...................................................................................................................................................................................... 172 Removal................................................................................................................................................................................. 172 Service................................................................................................................................................................................. 172 Installation............................................................................................................................................................................ 172 SECTION C5 AIR CLEANERS INDEX................................................................................................................................................................... 173 AIR CLEANERS.................................................................................................................................................................................... 175 OPERATION................................................................................................................................................................................... 175 SERVICING THE AIR CLEANERS.................................................................................................................................................................. 175 Replacing The Elements.................................................................................................................................................................. 176 AIR CLEANER ASSEMBLY CLEANING............................................................................................................................................................... 177 Primary Element Cleaning................................................................................................................................................................ 177 Precleaner Section Cleaning............................................................................................................................................................. 179 AIR INTAKE TROUBLESHOOTING.................................................................................................................................................................. 180 SECTION C7 FAN CLUTCH INDEX..................................................................................................................................................................... 181 FAN CLUTCH...................................................................................................................................................................................... 183 REMOVAL & INSTALLATION TOOLING.............................................................................................................................................................. 183 DISASSEMBLY................................................................................................................................................................................. 186 CLEANING AND INSPECTION..................................................................................................................................................................... 196 ASSEMBLY.................................................................................................................................................................................... 200 TEST PROCEDURE.............................................................................................................................................................................. 214 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX........................................................................................................................................ 215 SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM INDEX................................................................................................................................................. 217 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................................................................................... 219 ELECTRICAL SYSTEM DESCRIPTION............................................................................................................................................................... 219 BATTERIES................................................................................................................................................................................... 219 Maintenance and Service................................................................................................................................................................. 219 Troubleshooting......................................................................................................................................................................... 219 BATTERY SUPPLY SYSTEM....................................................................................................................................................................... 221 24VDC Battery Charging Alternator....................................................................................................................................................... 221 Battery Box............................................................................................................................................................................. 221 Removal................................................................................................................................................................................. 221 Installation............................................................................................................................................................................ 222 Battery Control Box..................................................................................................................................................................... 222 24VDC Auxiliary Battery Receptacles..................................................................................................................................................... 222 Engine Start Relay...................................................................................................................................................................... 222 ISOLATION BOX ASSEMBLY...................................................................................................................................................................... 222 Engine Shutdown Switch.................................................................................................................................................................. 222 Access Ladder Light Switch.............................................................................................................................................................. 222 Battery Disconnect Switches............................................................................................................................................................. 222 Propel Lockout Lever.................................................................................................................................................................... 223 LED Lights.............................................................................................................................................................................. 223 AUXILIARY CONTROL CABINET................................................................................................................................................................... 224 24VDC to 12VDC Converter................................................................................................................................................................ 224 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)......................................................................................................................................... 225 Operation............................................................................................................................................................................... 225 Pressure Switch......................................................................................................................................................................... 225 Check Valve............................................................................................................................................................................. 225 Timer Solenoid.......................................................................................................................................................................... 225 MAINTENANCE................................................................................................................................................................................. 226 Prelube System Operation Checks......................................................................................................................................................... 226 Check Valve............................................................................................................................................................................. 226 Timer Solenoid.......................................................................................................................................................................... 226 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.................................................................................................................................................. 227 24VDC ELECTRIC START SYSTEM..................................................................................................................................................................... 229 CRANKING MOTORS............................................................................................................................................................................. 229 Operation............................................................................................................................................................................... 229 Removal................................................................................................................................................................................. 229 Installation............................................................................................................................................................................ 229 CRANKING MOTOR TROUBLESHOOTING.............................................................................................................................................................. 230 Preliminary Inspection.................................................................................................................................................................. 230 No-Load Test............................................................................................................................................................................ 230 Interpreting Results of Tests........................................................................................................................................................... 231 Disassembly............................................................................................................................................................................. 231 Cleaning and Inspection................................................................................................................................................................. 232 Armature Servicing...................................................................................................................................................................... 234 Field Coil Checks....................................................................................................................................................................... 234 Field Coil Removal...................................................................................................................................................................... 234 SOLENOID CHECKS............................................................................................................................................................................. 235 Test.................................................................................................................................................................................... 235 Assembly................................................................................................................................................................................ 236 Bearing Replacement:.................................................................................................................................................................... 236 Motor Assembly:......................................................................................................................................................................... 236 Pinion Clearance........................................................................................................................................................................ 237 MAGNETIC SWITCH............................................................................................................................................................................. 237 Removal................................................................................................................................................................................. 237 Installation............................................................................................................................................................................ 237 Coil Test............................................................................................................................................................................... 238 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX............................................................................................................................................. 239 24 VDC ELECTRICAL SYSTEM COMPONENTS............................................................................................................................................................. 241 TRUCK SHUTDOWN PROCEDURE.................................................................................................................................................................... 241 BRAKE WARNING BUZZER........................................................................................................................................................................ 241 AUXILIARY CONTROL CABINET COMPONENTS........................................................................................................................................................ 241 Interface Module........................................................................................................................................................................ 242 Payload Meter........................................................................................................................................................................... 242 24VDC to 12VDC Converter................................................................................................................................................................ 242 Circuit Breaker (CB60).................................................................................................................................................................. 242 Inclinometer............................................................................................................................................................................ 242 Vehicle Electrical Center (VEC)......................................................................................................................................................... 243 Pump Module Service Light Timer......................................................................................................................................................... 243 Power Distribution Terminals............................................................................................................................................................ 243 Ground Terminal......................................................................................................................................................................... 243 Relays.................................................................................................................................................................................. 244 Engine Service Light Timer.............................................................................................................................................................. 244 RTMR1 - VEC Block....................................................................................................................................................................... 245 VEC-89.................................................................................................................................................................................. 246 VEC-90.................................................................................................................................................................................. 248 VEC-91.................................................................................................................................................................................. 250 MAGNETIC SWITCHES........................................................................................................................................................................... 252 Body position switches (With proximity switch and magnet)............................................................................................................................... 252 Proximity switch operation.......................................................................................................................................................... 252 Service............................................................................................................................................................................. 252 BODY-UP SWITCH.......................................................................................................................................................................... 253 Adjust the body up switch........................................................................................................................................................... 253 HOIST LIMIT SWITCH...................................................................................................................................................................... 254 Operation........................................................................................................................................................................... 254 Adjust the hoist limit switch....................................................................................................................................................... 255 KOMTRAX PLUS.................................................................................................................................................................................... 259 KOMTRAX PLUS BASIC FEATURES................................................................................................................................................................. 259 Gather Data............................................................................................................................................................................. 259 Convert and Record Data................................................................................................................................................................. 259 Communicate Data to Off-Board Systems................................................................................................................................................... 260 USING KOMTRAX PLUS.......................................................................................................................................................................... 261 Turning KOMTRAX Plus ON................................................................................................................................................................. 261 Normal KOMTRAX Plus Operation........................................................................................................................................................... 261 Turning KOMTRAX Plus OFF................................................................................................................................................................ 262 Downloading from the KOMTRAX Plus Controller............................................................................................................................................ 262 KOMTRAX PLUS DATA ITEMS..................................................................................................................................................................... 263 Fault Codes............................................................................................................................................................................. 263 Machine History......................................................................................................................................................................... 263 KOMTRAX Plus History.................................................................................................................................................................... 263 Snapshots............................................................................................................................................................................... 264 Manual Snapshots........................................................................................................................................................................ 264 Trends.................................................................................................................................................................................. 266 Histogram (Load Map) Data............................................................................................................................................................... 266 Haul Cycle Data......................................................................................................................................................................... 267 Alarm and Snapshot Triggers............................................................................................................................................................. 268 Satellite Features...................................................................................................................................................................... 268 KOMTRAX PLUS DIAGNOSTIC FEATURES............................................................................................................................................................ 270 Fault History........................................................................................................................................................................... 270 LED Digits.............................................................................................................................................................................. 270 KOMTRAX PLUS CONTROLLER..................................................................................................................................................................... 270 Removal................................................................................................................................................................................. 271 Installation............................................................................................................................................................................ 271 KOMTRAX PLUS SOFTWARE....................................................................................................................................................................... 272 VHMS Tool Box Installation.............................................................................................................................................................. 272 VHMS Setting Tool Installation.......................................................................................................................................................... 272 PDM Software Installation............................................................................................................................................................... 272 KOMTRAX PLUS INITIALIZATION PROCEDURE....................................................................................................................................................... 273 CONTROLLER SETUP PROCEDURE.............................................................................................................................................................. 273 SNAPSHOT PROCEDURE...................................................................................................................................................................... 276 DOWNLOAD PROCEDURE...................................................................................................................................................................... 277 FTP UPLOAD PROCEDURE.................................................................................................................................................................... 278 INITIALIZATION FORMS.................................................................................................................................................................... 279 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................................................................................... 280 KOMTRAX PLUS CONTROLLER CHECKOUT............................................................................................................................................................ 285 Necessary Equipment..................................................................................................................................................................... 285 Preliminary............................................................................................................................................................................. 285 KOMTRAX Plus Controller Checkout Procedure.............................................................................................................................................. 286 ORBCOMM CONTROLLER (if equipped)............................................................................................................................................................ 288 Removal................................................................................................................................................................................. 288 Installation............................................................................................................................................................................ 288 SECTION D11 KOMTRAX PLUS INDEX.................................................................................................................................................................. 257 INTERFACE MODULE............................................................................................................................................................................ 292 Removal................................................................................................................................................................................. 292 Installation............................................................................................................................................................................ 292 SENSORS..................................................................................................................................................................................... 293 Temperature Sensors..................................................................................................................................................................... 293 Pressure Sensors........................................................................................................................................................................ 293 INTERFACE MODULE SOFTWARE................................................................................................................................................................... 294 Flashburn Program Installation.......................................................................................................................................................... 294 Interface Module Application Code Installation.......................................................................................................................................... 295 Interface Module Realtime Data Monitor Software......................................................................................................................................... 295 INTERFACE MODULE CHECKOUT................................................................................................................................................................... 296 Necessary Equipment..................................................................................................................................................................... 296 Preliminary............................................................................................................................................................................. 297 Check Digital Inputs To The Interface Module............................................................................................................................................ 298 Check Analog Inputs To The Interface Module............................................................................................................................................. 302 Check Serial Interfaces To The Interface Module......................................................................................................................................... 302 Check Outputs From The Interface Module................................................................................................................................................. 303 SECTION D12 INTERFACE MODULE INDEX.............................................................................................................................................................. 289 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX............................................................................................................................. 309 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................................................................................... 311 GENERAL..................................................................................................................................................................................... 311 TROUBLESHOOTING............................................................................................................................................................................. 312 Communications Networks................................................................................................................................................................. 312 Coaxial Cable........................................................................................................................................................................... 312 FAULT CODES................................................................................................................................................................................. 312 Fault History........................................................................................................................................................................... 312 KOMTRAX Plus LED Display Fault Codes.................................................................................................................................................... 313 Chassis Fault Codes..................................................................................................................................................................... 314 Engine Fault Codes...................................................................................................................................................................... 318 FAULT TREE ANALYSIS......................................................................................................................................................................... 324 Unable to connect to KOMTRAX Plus from laptop PC........................................................................................................................................ 324 Flashing Error Code N4-23 (PLM III Communications Fault)................................................................................................................................ 325 Flashing Error Code N4-22 (Engine Communications Fault)................................................................................................................................. 326 No Data Received By WebCARE............................................................................................................................................................. 327 Coaxial Cable Troubleshooting........................................................................................................................................................... 328 SECTION D14 KOMTRAX PLUS FORMS INDEX............................................................................................................................................................ 329 KOMTRAX PLUS FORMS.............................................................................................................................................................................. 331 KOMTRAX PLUS INITIALIZATION CHECK LIST...................................................................................................................................................... 331 KOMTRAX PLUS DATA DOWNLOAD.................................................................................................................................................................. 332 KOMTRAX PLUS INITIALIZATION CHECK LIST...................................................................................................................................................... 333 KOMTRAX PLUS INITIALIZATION FORM............................................................................................................................................................ 335 SECTION E ELECTRIC PROPULSION SYSTEM INDEX...................................................................................................................................................... 337 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX.......................................................................................................................................... 339 ELECTRICAL PROPULSION SYSTEM COMPONENTS......................................................................................................................................................... 341 GENERAL SYSTEM DESCRIPTION.................................................................................................................................................................. 341 SYSTEM COMPONENTS........................................................................................................................................................................... 343 Drive System Controller (DSC)........................................................................................................................................................... 343 Diagnostic Information Display (DID) Panel.............................................................................................................................................. 344 DID Panel Event Codes................................................................................................................................................................... 344 DSC SOFTWARE FUNCTIONS...................................................................................................................................................................... 363 Input Processing........................................................................................................................................................................ 363 State Machine........................................................................................................................................................................... 363 DC Link State........................................................................................................................................................................... 366 Engine Control.......................................................................................................................................................................... 367 ALTERNATOR FIELD CONTROL.................................................................................................................................................................... 367 Desired Three-Phase Voltage............................................................................................................................................................. 367 Desired DC Link Voltage................................................................................................................................................................. 367 Self-Load............................................................................................................................................................................... 368 Propel Torque Control................................................................................................................................................................... 368 Retard Torque Control................................................................................................................................................................... 368 Wheel Slide Control..................................................................................................................................................................... 369 Resistor Grid Control................................................................................................................................................................... 369 Chopper Voltage Control................................................................................................................................................................. 369 EVENT DETECTION AND PROCESSING.............................................................................................................................................................. 369 Power-On Tests.......................................................................................................................................................................... 369 Initiated Tests......................................................................................................................................................................... 370 Periodic Tests.......................................................................................................................................................................... 370 EVENT RESTRICTIONS.......................................................................................................................................................................... 370 EVENT LOGGING AND STORAGE................................................................................................................................................................... 370 Event History Buffer.................................................................................................................................................................... 371 Data Packs.............................................................................................................................................................................. 371 Event Reset............................................................................................................................................................................. 371 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................................................................................... 372 Fast Start.............................................................................................................................................................................. 372 Engine Shutdown/Engine Not Running...................................................................................................................................................... 372 Limp Home Mode.......................................................................................................................................................................... 372 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS....................................................................................................................................... 373 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................................................................................... 380 Removal................................................................................................................................................................................. 380 Installation............................................................................................................................................................................ 380 Disassembly............................................................................................................................................................................. 380 Assembly................................................................................................................................................................................ 380 PHASE MODULE REPLACEMENT.................................................................................................................................................................... 381 Removal................................................................................................................................................................................. 381 Installation............................................................................................................................................................................ 381 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX.................................................................................................................................. 383 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................................................................................... 385 AC DRIVE SYSTEM MAINTENANCE................................................................................................................................................................. 385 NORMAL TRUCK SHUTDOWN PROCEDURE............................................................................................................................................................. 386 TEST EQUIPMENT.............................................................................................................................................................................. 387 HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS............................................................................................................................................. 387 REST MODE ACTIVATION........................................................................................................................................................................ 387 INITIAL CHECKOUT PROCEDURES................................................................................................................................................................. 388 Circuit Continuity and Resistance Checks................................................................................................................................................ 388 Megger Test for Grounds................................................................................................................................................................. 388 Troubleshooting for Grounds............................................................................................................................................................. 391 Low Voltage Power Supply Checks......................................................................................................................................................... 392 Drive System Controller (DCS) Card Checks............................................................................................................................................... 393 Propulsion System Software Installation................................................................................................................................................. 393 DSC Manual Test Procedures.............................................................................................................................................................. 396 Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks............................................................................................................ 398 Set Truck ID Number..................................................................................................................................................................... 402 Control Cabinet Pressure Switch Check................................................................................................................................................... 403 CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX)............................................................................................................................................. 404 Verifying DSC Software Version.......................................................................................................................................................... 404 Resetting and Erasing DSC Event Data.................................................................................................................................................... 405 ENGINE RUNNING TESTS........................................................................................................................................................................ 406 Battery Boost Circuit Verification...................................................................................................................................................... 406 Selector Switch Check................................................................................................................................................................... 408 Ground Detection Network Tests.......................................................................................................................................................... 411 Self Load Engine Test (Loadbox) Procedure............................................................................................................................................... 415 DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL.................................................................................................................................................. 417 DID Panel Display Selection............................................................................................................................................................. 417 DID Modes Display....................................................................................................................................................................... 419 Function Key F1 - DID Events or Faults Display.......................................................................................................................................... 420 Function Key F4 - DID Menu Display...................................................................................................................................................... 423 DID Self Load Engine Test (Loadbox)..................................................................................................................................................... 424 DID Link Capacitance Test............................................................................................................................................................... 426 DID Speedometer Test.................................................................................................................................................................... 427 DID View Software Version............................................................................................................................................................... 428 DID View Overspeed Setting.............................................................................................................................................................. 429 DID View Data Menu...................................................................................................................................................................... 430 DID Inverter Cutout Menu................................................................................................................................................................ 435 DID Truck Configuration Menu............................................................................................................................................................ 436 Language Selection...................................................................................................................................................................... 441 VIEWING EVENT AND STATISTICAL DATA.......................................................................................................................................................... 442 Viewing the DSC Event Summary, Trigger Data, and Data Packs............................................................................................................................. 442 Viewing the Statistical Data............................................................................................................................................................ 444 LOGIC SCREENS............................................................................................................................................................................... 445 DATALOGGER FUNCTION......................................................................................................................................................................... 447 Setting Up the Datalogger............................................................................................................................................................... 447 Starting the Datalogger................................................................................................................................................................. 449 UPLOADING DATA.............................................................................................................................................................................. 451 Consolidated Truck Data Save............................................................................................................................................................ 451 USB Drive............................................................................................................................................................................... 452 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX........................................................................................................................................ 453 Fault Code A001: Left front suspension pressure sensor signal is high....................................................................................................................... 455 Related circuit diagram................................................................................................................................................................. 455 Fault Code A002: Left front suspension pressure sensor signal is low........................................................................................................................ 456 Related circuit diagram................................................................................................................................................................. 456 Fault Code A003: Right front suspension pressure sensor signal is high...................................................................................................................... 457 Related circuit diagram................................................................................................................................................................. 457 Fault Code A004: Right front suspension pressure sensor signal is low....................................................................................................................... 458 Related circuit diagram................................................................................................................................................................. 458 Fault Code A005: Left rear suspension pressure sensor signal is high........................................................................................................................ 459 Related circuit diagram................................................................................................................................................................. 459 Fault Code A006: Left rear suspension pressure sensor signal is low......................................................................................................................... 460 Related circuit diagram................................................................................................................................................................. 460 Fault Code A007: Right rear suspension pressure sensor signal is high....................................................................................................................... 461 Related circuit diagram................................................................................................................................................................. 461 Fault Code A008: Right rear suspension pressure sensor signal is low........................................................................................................................ 462 Related circuit diagram................................................................................................................................................................. 462 Fault Code A009: Incline sensor signal is high.............................................................................................................................................. 463 Related circuit diagram................................................................................................................................................................. 463 Fault Code A010: Incline sensor signal is low............................................................................................................................................... 464 Related circuit diagram................................................................................................................................................................. 464 Fault Code A011: Payload meter speed sensor signal has failed............................................................................................................................... 465 Related circuit diagram................................................................................................................................................................. 465 Fault Code A013: Body up switch has failed.................................................................................................................................................. 466 Related circuit diagram................................................................................................................................................................. 466 Fault Code A014: Payload meter checksum computation has failed.............................................................................................................................. 467 Related circuit diagram................................................................................................................................................................. 467 Fault Code A016: Payload meter write to flash memory has failed............................................................................................................................. 468 Related circuit diagram................................................................................................................................................................. 468 Fault Code A017: Payload meter flash memory read has failed................................................................................................................................. 469 Related circuit diagram................................................................................................................................................................. 469 Fault Code A018: Right rear flat suspension cylinder warning................................................................................................................................ 470 Related circuit diagram................................................................................................................................................................. 471 Fault Code A019: Left rear flat suspension cylinder warning................................................................................................................................. 472 Related circuit diagram................................................................................................................................................................. 473 Fault Code A022: Carryback load is excessive................................................................................................................................................ 474 Related circuit diagram................................................................................................................................................................. 475 Fault Code A101: High pressure detected across a hydraulic pump filter...................................................................................................................... 476 Related circuit diagram................................................................................................................................................................. 477 Fault Code A103: Hydraulic oil tank temperature sensor is reading low....................................................................................................................... 478 Related circuit diagram................................................................................................................................................................. 478 Fault Code A104: Hydraulic oil tank temperature sensor is reading high...................................................................................................................... 479 Related circuit diagram................................................................................................................................................................. 479 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................................................................................. 480 Related circuit diagram................................................................................................................................................................. 481 Fault Code A107: GE has generated a propel system caution................................................................................................................................... 482 Related circuit diagram................................................................................................................................................................. 482 Fault Code A108: GE has generated a propel system temperature caution....................................................................................................................... 483 Related circuit diagram................................................................................................................................................................. 483 Fault Code A109: GE has generated a propel system reduced level signal...................................................................................................................... 484 Related circuit diagram................................................................................................................................................................. 484 Fault Code A111 & A247: Low steering pressure warning....................................................................................................................................... 486 Related circuit diagram................................................................................................................................................................. 487 Fault Code A115: Low steering precharge pressure is detected................................................................................................................................ 488 Related circuit diagram................................................................................................................................................................. 489 Fault Code A117 & A261: Low brake accumulator pressure warning.............................................................................................................................. 490 Related circuit diagram..................................................................................................................................................................... 491 Fault Code A118: Brake pressure is low while brake lock is activated........................................................................................................................ 492 Related circuit diagram..................................................................................................................................................................... 493 Fault Code A123: GE has generated a reduced retarding caution............................................................................................................................... 494 Related circuit diagram................................................................................................................................................................. 494 Fault Code A124: GE has generated a no propel / no retard warning........................................................................................................................... 495 Related circuit diagram................................................................................................................................................................. 495 Fault Code A125: GE has generated a no propel warning....................................................................................................................................... 496 Related circuit diagram................................................................................................................................................................. 496 Fault Code A126: Oil level in the hydraulic tank is low..................................................................................................................................... 497 Related circuit diagram................................................................................................................................................................. 497 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................................................................................. 498 Related circuit diagram................................................................................................................................................................. 499 Fault Code A128: IM furnished +5 volt output for sensors is high............................................................................................................................ 500 Related circuit diagram................................................................................................................................................................. 501 Fault Code A139 & A310: Low fuel level warning.............................................................................................................................................. 502 Related circuit diagram................................................................................................................................................................. 503 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.................................................................. 504 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.................................................................. 505 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A261) INDEX........................................................................................................................................ 507 Fault Code A152: Starter failure............................................................................................................................................................ 509 Fault Code A153: Battery voltage is low with truck in operation............................................................................................................................. 510 Fault Code A154: Battery charging voltage is excessive...................................................................................................................................... 511 Fault Code A155: Battery charging voltage is low............................................................................................................................................ 512 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level............................................................................................... 513 Fault Code A166: The Left Rear Hydraulic Oil Temp Sensor is low............................................................................................................................. 514 Fault Code A167: The Right Rear Hydraulic Oil Temp Sensor is low............................................................................................................................ 515 Fault Code A168: The Left Front Hydraulic Oil Temp Sensor is low............................................................................................................................ 516 Fault Code A169: The Right Front Hydraulic Oil Temp Sensor is low........................................................................................................................... 517 Fault Code A170: The Left Rear Hydraulic Oil Temp Sensor is high............................................................................................................................ 518 Fault Code A171: The Right Rear Hydraulic Oil Temp Sensor is high........................................................................................................................... 519 Fault Code A172: The Left Front Hydraulic Oil Temp Sensor is high........................................................................................................................... 520 Fault Code A173: The Right Front Hydraulic Oil Temp Sensor is high.......................................................................................................................... 521 Fault Code A184: J1939 data link is not connected........................................................................................................................................... 522 Fault Code A190: Auto lube control has detected an incomplete lube cycle.................................................................................................................... 523 Fault Code A193: Hydraulic tank oil temperature is high..................................................................................................................................... 524 Fault Code A194: Left front hydraulic oil temperature is high............................................................................................................................... 525 Fault Code A195: Right Front Hydraulic Oil Temperature is high.............................................................................................................................. 526 Fault Code A196: Left Rear Hydraulic Oil Temperature is high................................................................................................................................ 527 Fault Code A197: Right Rear Hydraulic Oil Temperature is high............................................................................................................................... 528 Fault Code A198: Hoist pressure 1 sensor is high............................................................................................................................................ 529 Fault Code A199: Hoist pressure 2 sensor is high............................................................................................................................................ 530 Fault Code A200: Steering pressure sensor is high........................................................................................................................................... 531 Fault Code A201: Brake pressure sensor is high.............................................................................................................................................. 532 Fault Code A202: Hoist pressure 1 sensor is low............................................................................................................................................. 533 Fault Code A203: Hoist pressure 2 sensor is low............................................................................................................................................. 534 Fault Code A204: Steering pressure sensor is low............................................................................................................................................ 535 Fault Code A205: Brake pressure sensor is low............................................................................................................................................... 536 Fault Code A206: Ambient temperature sensor is high......................................................................................................................................... 537 Fault Code A207: Ambient temperature sensor is low.......................................................................................................................................... 538 Fault Code A212: Bad truck speed signal..................................................................................................................................................... 539 Fault Code A213: Parking brake should have applied but is detected as not having applied.................................................................................................... 540 Fault Code A214: Parking brake should have released but is detected as not having released.................................................................................................. 542 Fault Code A215: The brake auto apply relay circuit is defective............................................................................................................................ 544 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit.................................................................................... 546 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................................................................................. 547 Fault Code A230: Parking brake has been requested while truck still moving.................................................................................................................. 548 Fault Code A231: Dump body is up while traveling or intending to travel..................................................................................................................... 549 Fault Code A235: Steering accumulator is in the process of being bled down.................................................................................................................. 550 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds........................................................................................................... 551 Fault Code A237: The CAN/RPC connection to the display is open.............................................................................................................................. 552 Fault Code A240: The keyswitch input to the interface module is open........................................................................................................................ 553 Fault Code A242: The fuel gauge within the display panel is defective....................................................................................................................... 554 Fault Code A243: The engine coolant temp gauge within the display panel is defective........................................................................................................ 555 Fault Code A244: The drive system temp gauge within the display panel is defective.......................................................................................................... 556 Fault Code A245: The hydraulic oil temp gauge within the display panel is defective......................................................................................................... 557 Fault Code A246: Payload meter reports truck overload....................................................................................................................................... 558 Fault Code A247 & A111: Low steering pressure warning....................................................................................................................................... 559 Related circuit diagram................................................................................................................................................................. 560 Fault Code A261 & A117: Low brake accumulator pressure warning.............................................................................................................................. 561 Related circuit diagram..................................................................................................................................................................... 562 SECTION E5 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX........................................................................................................................................ 563 Fault Code A248: The status indicator module within the display panel is defective.......................................................................................................... 565 Fault Code A249: The red warning lamp within the display panel is shorted................................................................................................................... 566 Fault Code A250: Battery voltage is low with the truck parked............................................................................................................................... 567 Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground....................................................................................... 569 Fault Code A252: Start enable output circuit is either open or shorted to ground............................................................................................................ 570 Fault Code A253: Steering bleed circuit is not open while running........................................................................................................................... 571 Fault Code A255: IM has detected a fault on IM output 1N.................................................................................................................................... 572 Fault Code A256: The red warning lamp within the display panel (driven by IM) is open....................................................................................................... 573 Fault Code A257: Payload CAN/RPC is not connected........................................................................................................................................... 574 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective............................................................................................................ 575 Fault Code A260: Parking brake failure...................................................................................................................................................... 576 Fault Code A262: Steering bleed valve circuit open during shutdown.......................................................................................................................... 578 Fault Code A264: Parking brake relay circuit is defective................................................................................................................................... 579 Fault Code A265: Service brake failure...................................................................................................................................................... 580 Fault Code A266: Selector lever was not in park while attempting to crank engine............................................................................................................ 581 Fault Code A267: Parking brake was not set while attempting to crank engine................................................................................................................. 582 Fault Code A268: Secondary engine shutdown while cranking................................................................................................................................... 583 Fault Code A270: Brake lock switch power supply is not on when required..................................................................................................................... 584 Fault Code A271: Shifter not in gear........................................................................................................................................................ 586 Fault Code A272: Brake lock switch power supply is not off when required.................................................................................................................... 587 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit..................................................................................... 589 Fault Code A274: A brake setting fault has been detected.................................................................................................................................... 590 Fault Code A275: A starter has been detected as engaged without a cranking attempt.......................................................................................................... 591 Fault Code A276: The drive system data link is not connected................................................................................................................................ 592 Fault Code A277: Parking brake applied while loading........................................................................................................................................ 593 Fault Code A278: Service brake applied while loading........................................................................................................................................ 594 Fault Code A279: Low steering pressure switch is defective.................................................................................................................................. 595 Fault Code A280: Steering accumulator Bleed Down switch is defective........................................................................................................................ 596 Fault Code A281: Brake lock degradation switch is defective................................................................................................................................. 597 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7........................................................................... 598 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................................................................................. 599 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated.................................................................................... 600 Fault Code A285: The parking brake was not set when the key switch was turned off........................................................................................................... 601 Fault Code A286: A fault was detected in the shutdown delay relay circuit................................................................................................................... 602 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off....................................................................................... 603 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX........................................................................................................................................ 605 Fault Code A303: Shifter is defective....................................................................................................................................................... 607 Fault Code A304: Auto lube grease level is low.............................................................................................................................................. 608 Fault Code A305: Auto lube circuit is defective............................................................................................................................................. 609 Fault Code A307: Both GE inverters are disabled............................................................................................................................................. 610 Fault Code A309: No brakes applied when expected............................................................................................................................................ 611 Fault Code A139 & A310: Low fuel level warning.............................................................................................................................................. 612 Related circuit diagram................................................................................................................................................................. 613 Fault Code A311: Brake lock switch is on when it should not be.............................................................................................................................. 614 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings.......................................................................................................... 615 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings......................................................................................................... 616 Fault Code A315: DC-DC converter 12 volt circuit is low..................................................................................................................................... 617 Fault Code A316: Starter engagement has been attempted with engine running.................................................................................................................. 618 Fault Code A317: Operation of brake auto apply circuit without a detected response.......................................................................................................... 619 Fault Code A318: Unexpected power loss to interface module.................................................................................................................................. 621 Fault Code A320: Propel system caution wire input not same as serial input.................................................................................................................. 622 Fault Code A321: Propel system temperature caution wire input not same as serial input...................................................................................................... 623 Fault Code A322: Propel system at reduced level wire input not same as serial input......................................................................................................... 624 Fault Code A323: Propel system at reduced retard level wire input not same as serial input.................................................................................................. 625 Fault Code A324: GE link voltage wire input not same as serial input........................................................................................................................ 626 Fault Code A325: No Propel/Retard wire input not same as serial input....................................................................................................................... 627 Fault Code A326: No Propel wire input not same as serial input.............................................................................................................................. 628 Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input.................................................................................................. 629 Fault Code A328: Drive system not powered up................................................................................................................................................ 630 Fault Code A329: Body down wire input not same as serial input.............................................................................................................................. 631 Fault Code A330: Dynamic retard switch input not same as serial input....................................................................................................................... 632 Fault Code A332: Seat belt not buckled...................................................................................................................................................... 633 Fault Code A334: Selector lever not in park when propel was either not ready or at rest..................................................................................................... 635 Fault Code A350: Overload on output 1B...................................................................................................................................................... 636 Fault Code A351: Overload on output 1E...................................................................................................................................................... 637 Fault Code A352: Overload on output 1H...................................................................................................................................................... 638 Fault Code A353: Overload on output 1J...................................................................................................................................................... 639 Fault Code A354: Overload on output 1K...................................................................................................................................................... 640 Fault Code A355: Overload on output 1L...................................................................................................................................................... 641 Fault Code A356: Overload on output 1M...................................................................................................................................................... 642 Fault Code A357: Overload on output 1N...................................................................................................................................................... 643 Fault Code A358: Overload on output 1P...................................................................................................................................................... 644 Fault Code A359: Overload on output 1R...................................................................................................................................................... 645 Fault Code A360: Overload on output 1S...................................................................................................................................................... 646 Fault Code A361: Overload on output 1T...................................................................................................................................................... 647 Fault Code A362: Overload on output 1U...................................................................................................................................................... 648 Fault Code A363: Overload on output 1X...................................................................................................................................................... 649 Fault Code A364: Overload on output 1Y...................................................................................................................................................... 650 Fault Code A365: Overload on output 1Z...................................................................................................................................................... 651 SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX.................................................................................................................................................. 653 SECTION G2 TIRES AND RIMS INDEX................................................................................................................................................................. 655 TIRES AND RIMS.................................................................................................................................................................................. 657 WHEEL STUD MAINTENANCE...................................................................................................................................................................... 658 FRONT TIRES AND RIMS........................................................................................................................................................................ 659 Removal................................................................................................................................................................................. 659 Installation............................................................................................................................................................................ 660 REAR TIRES AND RIMS......................................................................................................................................................................... 660 Removal................................................................................................................................................................................. 660 Installation............................................................................................................................................................................ 661 RIM......................................................................................................................................................................................... 662 Tire Removal............................................................................................................................................................................ 662 Tire Installation....................................................................................................................................................................... 662 SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX.................................................................................................................................................... 665 FRONT WHEEL HUB AND SPINDLE..................................................................................................................................................................... 667 WHEEL HUB AND SPINDLE ASSEMBLY.............................................................................................................................................................. 667 Removal................................................................................................................................................................................. 667 Spindle Removal Procedure (off of the truck)............................................................................................................................................ 670 Installation............................................................................................................................................................................ 672 Disassembly............................................................................................................................................................................. 673 Cleaning and Inspection................................................................................................................................................................. 675 Assembly................................................................................................................................................................................ 675 Wheel Bearing Adjustment................................................................................................................................................................ 676 Brake Installation...................................................................................................................................................................... 677 Seal Assembly Gap Check................................................................................................................................................................. 678 WHEEL SPEED SENSOR TESTING.................................................................................................................................................................. 679 STEERING CYLINDERS.......................................................................................................................................................................... 680 Spherical Bearing Wear Limits........................................................................................................................................................... 680 Removal................................................................................................................................................................................. 681 Installation............................................................................................................................................................................ 681 Bearing Replacement (Steering Cylinder and Tie Rod)..................................................................................................................................... 681 TIE ROD..................................................................................................................................................................................... 683 Removal................................................................................................................................................................................. 683 Installation............................................................................................................................................................................ 683 Disassembly............................................................................................................................................................................. 684 Assembly................................................................................................................................................................................ 684 Toe-In Adjustment....................................................................................................................................................................... 685 TIE ROD INSPECTION AND TORQUE PROCEDURE..................................................................................................................................................... 686 SECTION G4 REAR AXLE MOUNTING INDEX............................................................................................................................................................. 687 REAR AXLE MOUNTING.............................................................................................................................................................................. 689 PIVOT PIN................................................................................................................................................................................... 689 Removal................................................................................................................................................................................. 689 Installation............................................................................................................................................................................ 690 PIVOT EYE BEARING........................................................................................................................................................................... 690 Removal................................................................................................................................................................................. 690 Installation............................................................................................................................................................................ 690 PIVOT EYE REPAIR............................................................................................................................................................................ 691 Removal................................................................................................................................................................................. 691 Installation............................................................................................................................................................................ 691 ANTI-SWAY BAR............................................................................................................................................................................... 692 Removal................................................................................................................................................................................. 692 Disassembly............................................................................................................................................................................. 692 Cleaning and Inspection................................................................................................................................................................. 692 Assembly................................................................................................................................................................................ 692 Installation............................................................................................................................................................................ 692 SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX...................................................................................................................................................... 695 REAR AXLE AND WHEEL MOTOR....................................................................................................................................................................... 697 REAR AXLE HOUSING........................................................................................................................................................................... 697 Preparation............................................................................................................................................................................. 697 Removal................................................................................................................................................................................. 698 Cleaning and Inspection................................................................................................................................................................. 699 Installation............................................................................................................................................................................ 699 BLOWER PRESSURE SWITCH ADJUSTMENT........................................................................................................................................................... 699 WHEEL MOTOR................................................................................................................................................................................. 700 Preparation............................................................................................................................................................................. 700 Removal................................................................................................................................................................................. 701 Cleaning and Inspection................................................................................................................................................................. 703 Installation............................................................................................................................................................................ 703 WHEEL MOTOR GEAR OIL........................................................................................................................................................................ 708 Filtering Requirements.................................................................................................................................................................. 708 Particle Size Analysis.................................................................................................................................................................. 708 Flushing................................................................................................................................................................................ 708 Oil Sample Analysis..................................................................................................................................................................... 709 ELEMENT SPECIFICATION CHARTS................................................................................................................................................................ 710 SECTION H HYDRAIR® II SUSPENSIONS INDEX......................................................................................................................................................... 713 SECTION H2 FRONT SUSPENSIONS INDEX.............................................................................................................................................................. 715 FRONT SUSPENSION................................................................................................................................................................................ 717 Removal..................................................................................................................................................................................... 717 Installation................................................................................................................................................................................ 718 Inspection.................................................................................................................................................................................. 723 LOWER BEARING & SEALS....................................................................................................................................................................... 724 Removal................................................................................................................................................................................. 724 Installation............................................................................................................................................................................ 724 MAJOR SUSPENSION REBUILD.................................................................................................................................................................... 725 Disassembly............................................................................................................................................................................. 725 Assembly................................................................................................................................................................................ 726 SUSPENSION PRESSURE TEST.................................................................................................................................................................... 727 SECTION H3 REAR SUSPENSIONS INDEX............................................................................................................................................................... 729 REAR SUSPENSIONS................................................................................................................................................................................ 731 SUSPENSION CYLINDER......................................................................................................................................................................... 732 Removal................................................................................................................................................................................. 732 Installation............................................................................................................................................................................ 734 Disassembly............................................................................................................................................................................. 734 Cleaning and Inspection................................................................................................................................................................. 735 Assembly................................................................................................................................................................................ 735 SUSPENSION PRESSURE TEST.................................................................................................................................................................... 737 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX...................................................................................................................................... 739 SUSPENSION OILING AND CHARGING PROCEDURE........................................................................................................................................................ 741 GENERAL..................................................................................................................................................................................... 741 EQUIPMENT LIST.............................................................................................................................................................................. 741 HYDRAIR® CHARGING KIT....................................................................................................................................................................... 742 Installation of Charging Kit............................................................................................................................................................ 742 Removal of Charging Kit................................................................................................................................................................. 742 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS........................................................................................................................................... 743 FRONT SUSPENSION............................................................................................................................................................................ 743 Front Suspension Oiling................................................................................................................................................................. 743 Front Suspension Nitrogen Charging...................................................................................................................................................... 745 REAR SUSPENSION............................................................................................................................................................................. 746 Rear Suspension Oiling.................................................................................................................................................................. 747 Rear Suspension Nitrogen Charging....................................................................................................................................................... 749 OIL AND NITROGEN SPECIFICATIONS CHARTS.......................................................................................................................................................... 750 SECTION J BRAKE CIRCUIT INDEX................................................................................................................................................................... 751 SECTION J2 BRAKE CIRCUIT INDEX.................................................................................................................................................................. 753 BRAKE CIRCUIT................................................................................................................................................................................... 755 SERVICE BRAKE CIRCUIT....................................................................................................................................................................... 755 PARKING BRAKE CIRCUIT....................................................................................................................................................................... 757 BRAKE LOCK CIRCUIT.......................................................................................................................................................................... 757 SECONDARY BRAKING AND AUTOMATIC APPLY....................................................................................................................................................... 758 WARNING CIRCUIT............................................................................................................................................................................. 758 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX................................................................................................................................................ 761 BRAKE CIRCUIT COMPONENT SERVICE................................................................................................................................................................. 763 BRAKE VALVE................................................................................................................................................................................. 763 Rebuild Criteria........................................................................................................................................................................ 763 Removal................................................................................................................................................................................. 764 Installation............................................................................................................................................................................ 764 Disassembly............................................................................................................................................................................. 765 Cleaning and Inspection................................................................................................................................................................. 768 Assembly................................................................................................................................................................................ 768 Regulator Sleeve O-Ring Installation.................................................................................................................................................... 769 BRAKE VALVE BENCH TEST AND ADJUSTMENT....................................................................................................................................................... 771 Test Setup Procedure.................................................................................................................................................................... 772 Brake Valve Output Pressure Adjustment.................................................................................................................................................. 772 Final Test and Adjustment............................................................................................................................................................... 773 Installing Brake Pedal Actuator Assembly to Brake Valve................................................................................................................................. 773 Installing Retard Pedal To Brake Pedal.................................................................................................................................................. 773 DUAL RELAY VALVE............................................................................................................................................................................ 774 Removal................................................................................................................................................................................. 774 Installation............................................................................................................................................................................ 774 Disassembly............................................................................................................................................................................. 774 Cleaning and Inspection................................................................................................................................................................. 775 Assembly................................................................................................................................................................................ 776 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT.................................................................................................................................................. 777 Test Setup Procedure.................................................................................................................................................................... 778 Relay Valve Output Pressure Adjustment.................................................................................................................................................. 778 BRAKE MANIFOLD.............................................................................................................................................................................. 779 Removal................................................................................................................................................................................. 779 Installation............................................................................................................................................................................ 779 Disassembly............................................................................................................................................................................. 779 Cleaning and Inspection................................................................................................................................................................. 780 Assembly................................................................................................................................................................................ 780 BRAKE ACCUMULATORS.......................................................................................................................................................................... 780 Brake Accumulator bleed down Procedure.................................................................................................................................................. 780 Removal................................................................................................................................................................................. 781 Installation............................................................................................................................................................................ 781 Disassembly............................................................................................................................................................................. 782 Cleaning and Inspection................................................................................................................................................................. 783 Assembly................................................................................................................................................................................ 783 Accumulator Charging Procedure.......................................................................................................................................................... 785 Precharge Maintenance................................................................................................................................................................... 787 Accumulator Storage Procedures.......................................................................................................................................................... 788 Bladder Storage Procedures.............................................................................................................................................................. 788 Installing A Bladder Accumulator From Storage........................................................................................................................................... 788 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)............................................................................................................................................ 789 Removal................................................................................................................................................................................. 789 Installation............................................................................................................................................................................ 789 Disassembly............................................................................................................................................................................. 789 Lever Adjustments....................................................................................................................................................................... 789 Potentiometer Check..................................................................................................................................................................... 790 Assembly................................................................................................................................................................................ 790 FRONT BRAKE COOLING HOSE INSTALLATION....................................................................................................................................................... 792 Installation............................................................................................................................................................................ 792 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX.............................................................................................................................................. 795 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................................................................................... 797 REQUIRED EQUIPMENT.......................................................................................................................................................................... 798 INITIAL SYSTEM SETUP........................................................................................................................................................................ 799 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT...................................................................................................................................................... 800 AUTO APPLY (LOW BRAKE PRESSURE) CHECK-OUT................................................................................................................................................... 801 SERVICE BRAKES.............................................................................................................................................................................. 802 PARKING BRAKES.............................................................................................................................................................................. 802 PARKING BRAKE CONTROL LOGIC................................................................................................................................................................. 803 BRAKE LOCK CONTROL LOGIC.................................................................................................................................................................... 804 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART............................................................................................................................................. 807 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET........................................................................................................................................... 809 SECTION J5 WET DISC BRAKE ASSEMBLY INDEX........................................................................................................................................................ 815 WET DISC BRAKE ASSEMBLY......................................................................................................................................................................... 817 OPERATION................................................................................................................................................................................... 817 BRAKE DISC WEAR INSPECTION.................................................................................................................................................................. 818 BRAKE REBUILD............................................................................................................................................................................... 819 Disassembly............................................................................................................................................................................. 819 Cleaning and Inspection................................................................................................................................................................. 823 Assembly................................................................................................................................................................................ 824 Floating Ring Seal Assembly & Installation.............................................................................................................................................. 829 WET DISC BRAKE BLEEDING PROCEDURE........................................................................................................................................................... 833 SECTION J7 PARKING BRAKE INDEX.................................................................................................................................................................. 835 PARKING BRAKE................................................................................................................................................................................... 837 OPERATION................................................................................................................................................................................... 837 MAINTENANCE................................................................................................................................................................................. 838 Inspection.............................................................................................................................................................................. 838 Removal................................................................................................................................................................................. 838 Installation............................................................................................................................................................................ 839 Disassembly............................................................................................................................................................................. 839 Cleaning and Inspection................................................................................................................................................................. 839 Assembly................................................................................................................................................................................ 841 Cleaning and Inspecting New Discs....................................................................................................................................................... 842 PARKING BRAKE BLEEDING PROCEDURE............................................................................................................................................................ 843 SECTION L HYDRAULIC SYSTEM INDEX................................................................................................................................................................ 845 SECTION L2 HYDRAULIC SYSTEM INDEX............................................................................................................................................................... 847 HYDRAULIC SYSTEM................................................................................................................................................................................ 849 HYDRAULIC PUMP MODULE....................................................................................................................................................................... 849 HOIST CIRCUIT OPERATION..................................................................................................................................................................... 850 STEERING CIRCUIT OPERATION.................................................................................................................................................................. 852 DISC BRAKE COOLING SYSTEM................................................................................................................................................................... 854 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX.............................................................................................................................................. 857 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................................................................................... 859 HOIST PUMP.................................................................................................................................................................................. 859 Removal................................................................................................................................................................................. 859 Installation............................................................................................................................................................................ 861 Inspection.............................................................................................................................................................................. 866 Assembly................................................................................................................................................................................ 866 HOIST PUMP TROUBLESHOOTING GUIDE................................................................................................................................................................ 871 HYDRAULIC TANK.............................................................................................................................................................................. 872 Removal................................................................................................................................................................................. 872 Installation............................................................................................................................................................................ 873 HYDRAULIC TANK BREATHERS.................................................................................................................................................................... 873 HYDRAULIC TANK STRAINERS.................................................................................................................................................................... 874 Removal................................................................................................................................................................................. 874 Inspect and Clean....................................................................................................................................................................... 874 Installation............................................................................................................................................................................ 874 SECTION L4 STEERING CIRCUIT INDEX............................................................................................................................................................... 875 STEERING CIRCUIT................................................................................................................................................................................ 877 STEERING CIRCUIT OPERATION.................................................................................................................................................................. 877 COMPONENT DESCRIPTION....................................................................................................................................................................... 878 Steering Control Unit................................................................................................................................................................... 878 bleeddown Manifold...................................................................................................................................................................... 879 Steering Accumulator Bleeddown Solenoid................................................................................................................................................. 879 Relief Valves........................................................................................................................................................................... 881 Hoist Up Limit Solenoid................................................................................................................................................................. 881 Steering Accumulators................................................................................................................................................................... 881 Low Precharge Warning Switch............................................................................................................................................................ 881 High Pressure Filter.................................................................................................................................................................... 881 Quick Disconnect Ports.................................................................................................................................................................. 881 Flow Amplifier.......................................................................................................................................................................... 883 FLOW AMPLIFIER SYSTEM OPERATION............................................................................................................................................................. 884 No Steer................................................................................................................................................................................ 884 Steering Left........................................................................................................................................................................... 886 Steering Right.......................................................................................................................................................................... 888 No Steer, External Shock Load........................................................................................................................................................... 890 STEERING PUMP............................................................................................................................................................................... 892 Normal Operation........................................................................................................................................................................ 892 High Altitude Operation................................................................................................................................................................. 892 PRINCIPLE OF OPERATION...................................................................................................................................................................... 894 Full Pump Volume........................................................................................................................................................................ 894 Half Pump Volume........................................................................................................................................................................ 894 Neutral Position........................................................................................................................................................................ 894 Steering Pump........................................................................................................................................................................... 895 SECTION L5 STEERING CONTROL UNIT INDEX.......................................................................................................................................................... 897 STEERING CONTROL UNIT........................................................................................................................................................................... 899 REMOVAL..................................................................................................................................................................................... 899 SPLINE INSPECTION........................................................................................................................................................................... 899 INSTALLATION................................................................................................................................................................................ 900 DISASSEMBLY................................................................................................................................................................................. 900 CLEANING AND INSPECTION..................................................................................................................................................................... 901 ASSEMBLY.................................................................................................................................................................................... 903 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX.............................................................................................................................................. 907 STEERING CIRCUIT COMPONENT REPAIR............................................................................................................................................................... 909 BLEEDDOWN MANIFOLD VALVE.................................................................................................................................................................... 909 Removal................................................................................................................................................................................. 909 Installation............................................................................................................................................................................ 910 FLOW AMPLIFIER.............................................................................................................................................................................. 911 Removal................................................................................................................................................................................. 911 Installation............................................................................................................................................................................ 911 Disassembly............................................................................................................................................................................. 911 Assembly................................................................................................................................................................................ 913 STEERING CYLINDERS.......................................................................................................................................................................... 914 Disassembly............................................................................................................................................................................. 915 Piston Seal & Bearing Installation...................................................................................................................................................... 915 Assembly................................................................................................................................................................................ 915 Testing................................................................................................................................................................................. 915 STEERING AND BRAKE PUMP..................................................................................................................................................................... 916 Removal................................................................................................................................................................................. 916 Installation............................................................................................................................................................................ 917 Disassembly............................................................................................................................................................................. 918 Inspection.............................................................................................................................................................................. 921 Assembly................................................................................................................................................................................ 924 Driveshaft Group........................................................................................................................................................................ 925 Rotating Group.......................................................................................................................................................................... 925 Valve Plate Group....................................................................................................................................................................... 926 STEERING ACCUMULATORS....................................................................................................................................................................... 928 Removal................................................................................................................................................................................. 928 Installation............................................................................................................................................................................ 928 Disassembly............................................................................................................................................................................. 929 Cleaning and Inspection................................................................................................................................................................. 929 Assembly................................................................................................................................................................................ 930 Leak Testing............................................................................................................................................................................ 932 Charging Procedure...................................................................................................................................................................... 933 Precharge Maintenance................................................................................................................................................................... 935 Accumulator Storage Procedures.......................................................................................................................................................... 936 Bladder Storage Procedures.............................................................................................................................................................. 936 Installing A Bladder Accumulator From Storage........................................................................................................................................... 936 TROUBLESHOOTING................................................................................................................................................................................. 937 STEERING CIRCUIT............................................................................................................................................................................ 937 STEERING PUMP............................................................................................................................................................................... 939 Basic Hydraulic System Checks........................................................................................................................................................... 940 System Leakage Check.................................................................................................................................................................... 941 Steering Pump Troubleshooting Guide..................................................................................................................................................... 943 Pump Pressure Control Checks............................................................................................................................................................ 946 Pump Fails to Unload.................................................................................................................................................................... 947 Pump Fails to Develop Pressure.......................................................................................................................................................... 947 Pump Slow in Developing Pressure........................................................................................................................................................ 948 Pump Control Valve Inspection and Troubleshooting....................................................................................................................................... 949 Pump Case Drain Check................................................................................................................................................................... 949 Setting Pump Pressure Controls.......................................................................................................................................................... 951 Adjustment.............................................................................................................................................................................. 952 SECTION L7 HOIST CIRCUIT INDEX.................................................................................................................................................................. 953 HOIST CIRCUIT................................................................................................................................................................................... 955 BASIC OPERATION............................................................................................................................................................................. 955 COMPONENT DESCRIPTION....................................................................................................................................................................... 956 Hydraulic Tank.......................................................................................................................................................................... 956 Hydraulic Pump.......................................................................................................................................................................... 956 High Pressure Filters................................................................................................................................................................... 956 Hoist Valve............................................................................................................................................................................. 956 Inlet Sections.......................................................................................................................................................................... 956 Work Ports (Rear) Spool Section......................................................................................................................................................... 957 Tank Ports (Front) Spool Section........................................................................................................................................................ 957 Hoist Pilot Valve....................................................................................................................................................................... 957 Bleeddown Manifold...................................................................................................................................................................... 958 Hoist Up Limit Solenoid................................................................................................................................................................. 958 Pilot Operated Check Valve.............................................................................................................................................................. 958 Overcenter Manifold..................................................................................................................................................................... 958 HOIST CIRCUIT OPERATION......................................................................................................................................................................... 959 Float Position Of Pilot Valve With Truck Body On Frame...................................................................................................................................... 960 Power Up Operation.......................................................................................................................................................................... 962 Hold Operation.............................................................................................................................................................................. 964 Power Down Operation........................................................................................................................................................................ 966 Float Operation............................................................................................................................................................................. 968 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX................................................................................................................................................. 971 HOIST CIRCUIT COMPONENT REPAIR.................................................................................................................................................................. 973 HOIST VALVE................................................................................................................................................................................. 973 Removal................................................................................................................................................................................. 973 Installation............................................................................................................................................................................ 974 O-Ring Replacement...................................................................................................................................................................... 974 INLET SECTION............................................................................................................................................................................... 975 Disassembly............................................................................................................................................................................. 975 Cleaning and Inspection................................................................................................................................................................. 976 Assembly................................................................................................................................................................................ 976 REAR SPOOL SECTION (Work Ports)............................................................................................................................................................. 977 Disassembly............................................................................................................................................................................. 977 Cleaning and Inspection................................................................................................................................................................. 977 Assembly................................................................................................................................................................................ 979 FRONT SPOOL SECTION (Tank Ports)............................................................................................................................................................ 980 Disassembly............................................................................................................................................................................. 980 Cleaning and Inspection................................................................................................................................................................. 980 Assembly................................................................................................................................................................................ 980 HOIST PILOT VALVE........................................................................................................................................................................... 982 Removal................................................................................................................................................................................. 982 Installation............................................................................................................................................................................ 982 Disassembly............................................................................................................................................................................. 983 Cleaning and Inspection................................................................................................................................................................. 984 Assembly................................................................................................................................................................................ 984 HOIST CYLINDERS............................................................................................................................................................................. 985 Removal................................................................................................................................................................................. 985 Installation............................................................................................................................................................................ 986 Disassembly............................................................................................................................................................................. 988 Cleaning and Inspection................................................................................................................................................................. 989 Assembly - Quill........................................................................................................................................................................ 990 Assembly - Cylinder..................................................................................................................................................................... 992 Testing................................................................................................................................................................................. 992 OVERCENTER VALVE MANIFOLD................................................................................................................................................................... 993 SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX....................................................................................................................................................... 995 HYDRAULIC SYSTEM FILTERS........................................................................................................................................................................ 997 HOIST CIRCUIT FILTER........................................................................................................................................................................ 997 Filter Element Replacement.............................................................................................................................................................. 997 Removal - Hoist Circuit Filter.......................................................................................................................................................... 998 Installation - Hoist Circuit Filter..................................................................................................................................................... 998 Indicator Switch - Hoist Circuit Filter................................................................................................................................................. 998 STEERING CIRCUIT FILTER..................................................................................................................................................................... 999 Filter Element Replacement.............................................................................................................................................................. 999 Removal - Steering Circuit Filter.......................................................................................................................................................1000 Installation - Steering Circuit Filter..................................................................................................................................................1000 Indicator Switch - Steering Circuit Filter..............................................................................................................................................1000 INDICATOR SWITCH............................................................................................................................................................................1000 Test Procedure..........................................................................................................................................................................1000 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX..................................................................................................................................................1003 HYDRAULIC CHECKOUT PROCEDURE....................................................................................................................................................................1005 GENERAL INFORMATION.........................................................................................................................................................................1005 Procedure for Bleeding Down Hydraulic Brake and Steering Accumulators.......................................................................................................................1005 Accumulator Precharge Procedure (step 1)....................................................................................................................................................1006 Pressure Gauge Installation (steps 2 and 3).................................................................................................................................................1007 Initial Start-Up and Flushing (steps 4 through 20)..........................................................................................................................................1007 Steering System Checkout and Adjustment (steps 21 through 24)...............................................................................................................................1011 Steering Pump with Unloader Valve Adjustment (step 25)......................................................................................................................................1011 Steering System Diagnostic and Verification (steps 26 through 30)...........................................................................................................................1012 Hoist System Checkout and Adjustment (steps 31 through 33)..................................................................................................................................1013 Hoist Counterbalance Valve Adjustment (step 34).............................................................................................................................................1014 Oil Cleanliness Check (steps 35 & 36).......................................................................................................................................................1015 HYDRAULIC CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET......................................................................................................................................1016 SECTION M OPTIONS AND SPECIAL TOOLS INDEX.......................................................................................................................................................1019 SECTION M7 HOT START SYSTEM INDEX...............................................................................................................................................................1021 HOT START SYSTEM................................................................................................................................................................................1023 SYSTEM OPERATION............................................................................................................................................................................1023 HEATER INFORMATION..........................................................................................................................................................................1024 TROUBLESHOOTING GUIDELINES..................................................................................................................................................................1025 SPECIAL TOOLS...................................................................................................................................................................................1027 HIGH VOLTAGE TOOLS..........................................................................................................................................................................1031 0-2000 VDC CUSTOM METER KIT (58B-06-00800)..................................................................................................................................................1031 RADIATOR SHUTTERS...............................................................................................................................................................................1037 OPERATION...................................................................................................................................................................................1037 Hydraulic Circuit.......................................................................................................................................................................1037 Electrical Circuit......................................................................................................................................................................1038 MAINTENANCE AND REPAIR......................................................................................................................................................................1038 TROUBLESHOOTING.............................................................................................................................................................................1039 SECTION M19 RADIATOR SHUTTERS INDEX.............................................................................................................................................................1035 SECTION M20 PAYLOAD METER III ™ INDEX...........................................................................................................................................................1043 OPERATION SECTION...............................................................................................................................................................................1048 Introduction................................................................................................................................................................................1048 Data Summary............................................................................................................................................................................1048 Data Gathering..........................................................................................................................................................................1048 COMPONENT DESCRIPTION.......................................................................................................................................................................1049 System Diagram..........................................................................................................................................................................1049 Suspension Pressure Sensors.............................................................................................................................................................1049 Inclinometer............................................................................................................................................................................1049 Operator Display........................................................................................................................................................................1049 Operator Switch.........................................................................................................................................................................1050 Speed Input.............................................................................................................................................................................1050 Body-Up Switch..........................................................................................................................................................................1050 Brake Lock Switch.......................................................................................................................................................................1050 Payload Meter...........................................................................................................................................................................1050 Communications Ports....................................................................................................................................................................1050 Key Switch Input........................................................................................................................................................................1051 Payload Meter Power.....................................................................................................................................................................1051 Load Lights.............................................................................................................................................................................1051 Wiring and Termination..................................................................................................................................................................1052 TCI Outputs.............................................................................................................................................................................1052 OPERATOR’S DISPLAY AND SWITCH...............................................................................................................................................................1053 Reading the Speedometer/Digital Display.................................................................................................................................................1053 Reading the Load Display................................................................................................................................................................1053 Using the Operator ID...................................................................................................................................................................1053 Using the Load and Ton Counter..........................................................................................................................................................1053 Total Ton Counter.......................................................................................................................................................................1053 Total Load Counter......................................................................................................................................................................1054 Clearing the Counters...................................................................................................................................................................1054 Viewing Live Sensor Data................................................................................................................................................................1054 Other Display Messages..................................................................................................................................................................1054 PAYLOAD OPERATION & CALCULATION.............................................................................................................................................................1055 Description of Haul Cycle States........................................................................................................................................................1055 Haul Cycle Description..................................................................................................................................................................1055 Load Calculation........................................................................................................................................................................1056 Carry Back..............................................................................................................................................................................1056 Measurement Accuracy....................................................................................................................................................................1056 SOURCES FOR PAYLOAD ERROR...................................................................................................................................................................1056 Payload Error...........................................................................................................................................................................1056 Loading Conditions......................................................................................................................................................................1057 Pressure Sensors........................................................................................................................................................................1057 Swingloads..............................................................................................................................................................................1057 Speed and Distance......................................................................................................................................................................1057 HAUL CYCLE DATA.............................................................................................................................................................................1057 Haul Cycle Warning Flags................................................................................................................................................................1059 Frame Torque Data.......................................................................................................................................................................1060 Sprung Weight Data......................................................................................................................................................................1060 Maximum Speed Data......................................................................................................................................................................1060 Alarm Records...........................................................................................................................................................................1060 Fault Code Data.........................................................................................................................................................................1061 PC SOFTWARE OVERVIEW........................................................................................................................................................................1062 System Configuration....................................................................................................................................................................1062 Installing the PLMIII Software..........................................................................................................................................................1062 DOWNLOADING DATA............................................................................................................................................................................1063 PLM III SYSTEM CONFIGURATION................................................................................................................................................................1064 Starting Communications.................................................................................................................................................................1064 Displayed Payload Units.................................................................................................................................................................1064 Time Units..............................................................................................................................................................................1064 Connection Menu.........................................................................................................................................................................1064 Connecting to the Payload Meter.........................................................................................................................................................1065 Configure the Payload Meter.............................................................................................................................................................1065 Setting the Date and Time...............................................................................................................................................................1065 Setting the Truck Type..................................................................................................................................................................1066 Setting the Gauge Display Units.........................................................................................................................................................1066 Setting the Frame Serial Number.........................................................................................................................................................1066 Setting the Truck Number................................................................................................................................................................1066 Setting the Komatsu Distributor.........................................................................................................................................................1066 Setting the Komatsu Customer............................................................................................................................................................1066 Clean Truck Tare Calibration............................................................................................................................................................1067 Inclinometer Calibration................................................................................................................................................................1067 DATA ANALYSIS...............................................................................................................................................................................1068 Creating a Query........................................................................................................................................................................1068 Sorting on Truck Unit Number............................................................................................................................................................1068 Sorting on Truck Type...................................................................................................................................................................1068 Sorting on Date Range...................................................................................................................................................................1069 Sorting on Time Range...................................................................................................................................................................1069 Payload Detail Screen...................................................................................................................................................................1070 Creating Reports........................................................................................................................................................................1070 Summary - one page report...............................................................................................................................................................1071 Detailed - multi-page report............................................................................................................................................................1071 Creating Graphs.........................................................................................................................................................................1072 Exporting Data..........................................................................................................................................................................1072 CSV Export..............................................................................................................................................................................1072 Compressed..............................................................................................................................................................................1073 Importing Data..........................................................................................................................................................................1074 Deleting Haul Cycle Records.............................................................................................................................................................1074 Viewing Alarms..........................................................................................................................................................................1075 Deleting Alarm Records..................................................................................................................................................................1075 TROUBLESHOOTING SECTION.........................................................................................................................................................................1076 TROUBLESHOOTING.............................................................................................................................................................................1076 Viewing Active Alarms...................................................................................................................................................................1076 Real-Time Data Display..................................................................................................................................................................1076 Testing the Payload Lights..............................................................................................................................................................1076 Creating Log Files of Inputs............................................................................................................................................................1077 Daily Inspections.......................................................................................................................................................................1077 Periodic Maintenance....................................................................................................................................................................1077 Abnormal Displays at Power-Up...........................................................................................................................................................1078 No Payload Display When Key Switch is Turned ON.........................................................................................................................................1079 No Display on Speedometer...............................................................................................................................................................1080 No Display on Operator Display..........................................................................................................................................................1080 No Communications With PC...............................................................................................................................................................1081 Load Lights Don’t Light During Loading..................................................................................................................................................1082 Load Lights Remain ON...................................................................................................................................................................1084 Load Lights Remain ON During Dumping....................................................................................................................................................1084 Display Doesn't Clear When The Load Is Dumped...........................................................................................................................................1084 Calibration Problems....................................................................................................................................................................1085 Alarm 1 - Left Front Pressure High......................................................................................................................................................1086 Alarm 2 - Left Front Pressure Low.......................................................................................................................................................1086 Troubleshoot Wiring to Left Front Suspension............................................................................................................................................1086 Alarm 3 - Right Front Pressure High.....................................................................................................................................................1087 Alarm 4 - Right Front Pressure Low......................................................................................................................................................1087 Troubleshoot Wiring to Right Front Suspension...........................................................................................................................................1087 Alarm 5 -Left Rear Pressure High........................................................................................................................................................1088 Alarm 6 - Left Rear Pressure Low........................................................................................................................................................1088 Troubleshoot Wiring to Left Rear Suspension.............................................................................................................................................1088 Alarm 7 - Right Rear Pressure High......................................................................................................................................................1089 Alarm 8 - Right Rear Pressure Low.......................................................................................................................................................1089 Troubleshoot Wiring to Right Rear Suspension............................................................................................................................................1089 Alarm 9 - Inclinometer High.............................................................................................................................................................1090 Alarm 10 - Inclinometer Low.............................................................................................................................................................1090 Troubleshoot Inclinometer Wiring........................................................................................................................................................1090 Alarm 13 - Body Up Input Failure........................................................................................................................................................1091 Alarm 16 - Memory Write Failure.........................................................................................................................................................1092 Alarm 17 - Memory Read Failure..........................................................................................................................................................1092 Alarm 18................................................................................................................................................................................1093 Alarm 19................................................................................................................................................................................1093 Alarm 22................................................................................................................................................................................1093 Operator Switch Doesn't Work............................................................................................................................................................1094 Alarm 26 - User Switch Fault - SELECT...................................................................................................................................................1094 Alarm 27 - User Switch Fault - SET......................................................................................................................................................1094 Connector Map...........................................................................................................................................................................1095 Connectors..............................................................................................................................................................................1095 PLMIII CHECK OUT PROCEDURE......................................................................................................................................................................1096 General Description.........................................................................................................................................................................1096 Tools Required..............................................................................................................................................................................1096 Checkout Procedure..........................................................................................................................................................................1096 PLMIII CHECKOUT PROCEDURE CONFIRMATION......................................................................................................................................................1100 Flashburn Programming...................................................................................................................................................................1100 Confirmation Checklist..................................................................................................................................................................1102 SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX.....................................................................................................................................................1105 RESERVE ENGINE OIL SYSTEM.......................................................................................................................................................................1107 Operation...................................................................................................................................................................................1108 LED Monitor Light...........................................................................................................................................................................1108 Tank Fill Control (Optional)................................................................................................................................................................1109 Filling Procedure (Remote Fill Feature).....................................................................................................................................................1109 SERVICE.....................................................................................................................................................................................1110 Every 10 Hours, or once each shift:.....................................................................................................................................................1110 Every 500 Hours.........................................................................................................................................................................1110 Changing Oil............................................................................................................................................................................1110 TROUBLESHOOTING.............................................................................................................................................................................1111 Circuit Fuse............................................................................................................................................................................1111 SYSTEM ELECTRICAL SCHEMATICS................................................................................................................................................................1112 SECTION M32 RETRACTABLE LADDER SYSTEM INDEX.....................................................................................................................................................1113 RETRACTABLE LADDER SYSTEM.......................................................................................................................................................................1118 GENERAL SAFETY..............................................................................................................................................................................1118 LADDER SYSTEM DESCRIPTION...................................................................................................................................................................1118 LADDER SYSTEM OPERATION.....................................................................................................................................................................1118 Normal Operation........................................................................................................................................................................1118 Emergency Operation.....................................................................................................................................................................1120 Limit Switch Operation..................................................................................................................................................................1120 IN-CAB CONTROL PANEL........................................................................................................................................................................1120 IN-CAB CONTROL PANEL FEATURES...............................................................................................................................................................1122 Digital Display Screen..................................................................................................................................................................1122 Command Buttons.........................................................................................................................................................................1122 IN-CAB CONTROL PANEL FUNCTIONS..............................................................................................................................................................1124 Timing Control..........................................................................................................................................................................1124 Ladder System Status....................................................................................................................................................................1124 Fault Code Identification...............................................................................................................................................................1124 Ladder System Configuration.............................................................................................................................................................1125 In-Cab Control Panel Lockout............................................................................................................................................................1125 Automatic Raising.......................................................................................................................................................................1125 Diagnostics.............................................................................................................................................................................1125 Maintenance.............................................................................................................................................................................1125 USING THE IN-CAB CONTROL PANEL..............................................................................................................................................................1126 Raising the Ladder......................................................................................................................................................................1126 Lowering the Ladder.....................................................................................................................................................................1127 USING THE GROUND LEVEL CONTROL BOX..........................................................................................................................................................1128 Raising the Ladder......................................................................................................................................................................1128 Lowering the Ladder.....................................................................................................................................................................1128 POWER PACK OPERATION........................................................................................................................................................................1129 MAINTENANCE.................................................................................................................................................................................1133 Safety During Maintenance...............................................................................................................................................................1133 Unplanned Ladder Movements..............................................................................................................................................................1133 Automatic Ladder Raising................................................................................................................................................................1133 Automatic Accumulator Recharging (Ladder in UP position)................................................................................................................................1134 PREVENTIVE MAINTENANCE PROCEDURES...........................................................................................................................................................1135 Daily Inspection........................................................................................................................................................................1135 250 Hour Inspection.....................................................................................................................................................................1135 5000 Hour Inspection....................................................................................................................................................................1135 SERVICING...................................................................................................................................................................................1136 Check Reservoir Oil Level...............................................................................................................................................................1136 Changing RLS Fluid......................................................................................................................................................................1136 Cleaning the RLS........................................................................................................................................................................1137 RLS DIAGNOSTICS.............................................................................................................................................................................1137 Description of Diagnostics Features.....................................................................................................................................................1137 Continuous System Monitoring............................................................................................................................................................1138 Historic System Data Review.............................................................................................................................................................1139 Comms Integrity Monitoring..............................................................................................................................................................1139 Log and Service Information.............................................................................................................................................................1139 System Event Logs.......................................................................................................................................................................1140 SECURITY ACCESS LEVELS......................................................................................................................................................................1141 Access Level 1 – NONE...................................................................................................................................................................1141 Access Level 2 – RESTRICTED.............................................................................................................................................................1141 Access Level 3 – COMPLETE...............................................................................................................................................................1141 User Access Privileges..................................................................................................................................................................1142 USER ID – PASSWORD..........................................................................................................................................................................1143 Sequential Field Value Selection Options................................................................................................................................................1143 Password Character Table................................................................................................................................................................1143 USER ID – NEW USER SETUP....................................................................................................................................................................1144 SYSTEM FAULTS...............................................................................................................................................................................1144 Fault Type 1: Communications error......................................................................................................................................................1145 Fault Type 2: 10A/15A fuse blown........................................................................................................................................................1145 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected...............................................................................................................1146 Fault Type 8: Power pack recharge too long..............................................................................................................................................1146 Fault Type 9: Inhibit relay fail........................................................................................................................................................1147 Fault Types 10, 11: Light/Siren relay failure...........................................................................................................................................1147 Fault Type 12: Ladder came off upper limit..............................................................................................................................................1148 Fault Type 13: Ladder did not reach limit...............................................................................................................................................1148 Fault Type 14: Ladder stayed on limit...................................................................................................................................................1149 Fault Type 15: Low oil level............................................................................................................................................................1149 Fault Type 16: System voltage over 18V during movement..................................................................................................................................1150 Fault Type 17: System voltage under 18V.................................................................................................................................................1150 Fault Type 18: System voltage over 31V..................................................................................................................................................1151 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)..........................................................................................................1151 Fault Type 21: Accumulator recharge > than once/hour....................................................................................................................................1152 Fault Type 22: System raised by park brake..............................................................................................................................................1152 Fault Types 23, 24: Levels 1 and 2 service overdue......................................................................................................................................1153 Fault Type 25: Levels 1 and 2 service complete..........................................................................................................................................1153 DATA MANAGEMENT.............................................................................................................................................................................1154 Log Files...............................................................................................................................................................................1154 Generating Reports......................................................................................................................................................................1155 MENU DIAGRAMS...............................................................................................................................................................................1161 Controller Config.......................................................................................................................................................................1161 Contact Information.....................................................................................................................................................................1161 Show Recent Logs........................................................................................................................................................................1161 System Settings.........................................................................................................................................................................1161 Upload Logs to USB......................................................................................................................................................................1161 Diagnostics.............................................................................................................................................................................1161 SECTION M33 CAMERA SYSTEM INDEX.................................................................................................................................................................1169 CAMERA SYSTEM...................................................................................................................................................................................1171 CAMERA SYSTEM...............................................................................................................................................................................1171 General.................................................................................................................................................................................1171 Operation...............................................................................................................................................................................1171 Camera Switch...........................................................................................................................................................................1172 CAMERA MONITOR..............................................................................................................................................................................1173 General.................................................................................................................................................................................1173 CAMERA CONTROLLER...........................................................................................................................................................................1174 General.................................................................................................................................................................................1174 Removal.................................................................................................................................................................................1174 Installation............................................................................................................................................................................1174 Camera Controller Connector Pins........................................................................................................................................................1174 CAMERA SWITCHER.............................................................................................................................................................................1175 General.................................................................................................................................................................................1175 Removal.................................................................................................................................................................................1175 Installation............................................................................................................................................................................1175 SETUP AND CHECKOUT PROCEDURE................................................................................................................................................................1176 General.................................................................................................................................................................................1176 STEP 1 - Switch Function................................................................................................................................................................1176 STEP 2 - Monitor System Settings to Default.............................................................................................................................................1176 STEP 4 - Monitor Settings - System Settings Unique......................................................................................................................................1178 STEP 4 - Monitor Settings - System Settings Unique - Cameras............................................................................................................................1180 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay....................................................................................................................1182 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode.......................................................................................................................1183 STEP 7 - Integrated Functions Check.....................................................................................................................................................1184 SECTION N OPERATOR CAB INDEX....................................................................................................................................................................1185 SECTION N2 TRUCK CAB AND COMPONENTS INDEX.......................................................................................................................................................1187 TRUCK CAB AND COMPONENTS........................................................................................................................................................................1189 TRUCK CAB...................................................................................................................................................................................1189 Description.............................................................................................................................................................................1189 Removal.................................................................................................................................................................................1190 Installation............................................................................................................................................................................1191 CAB DOOR....................................................................................................................................................................................1192 Removal.................................................................................................................................................................................1192 Installation............................................................................................................................................................................1192 Door Jamb Bolt Adjustment...............................................................................................................................................................1193 Door Handle Plunger Adjustment..........................................................................................................................................................1194 Replacing the Door Glass................................................................................................................................................................1195 Replacing the Door Handle or Latch Assembly.............................................................................................................................................1199 Replacing the Door Window Regulator.....................................................................................................................................................1200 Replacing the Door and Door Hinge Seal..................................................................................................................................................1201 Replacing the Door Opening Seal.........................................................................................................................................................1201 GLASS REPLACEMENT (Adhesive-Bonded Windows).................................................................................................................................................1202 Recommended Tools and Supplies..........................................................................................................................................................1202 Replacement Procedure...................................................................................................................................................................1202 WINDSHIELD AND REAR GLASS...................................................................................................................................................................1203 Removal.................................................................................................................................................................................1203 Installation............................................................................................................................................................................1204 SECTION N3 CAB AND PASSENGER SEATS INDEX........................................................................................................................................................1205 CAB SEATS.......................................................................................................................................................................................1207 OPERATOR SEAT (STANDARD SEAT)...............................................................................................................................................................1207 Adjustment..............................................................................................................................................................................1207 Inspection..............................................................................................................................................................................1208 Removal.................................................................................................................................................................................1208 Installation............................................................................................................................................................................1208 Replacing the Seat Compressor...........................................................................................................................................................1209 PASSENGER SEAT (STANDARD SEAT)..............................................................................................................................................................1214 Inspection..............................................................................................................................................................................1214 Removal.................................................................................................................................................................................1214 Installation............................................................................................................................................................................1214 SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230).............................................................................................................................................1215 Removal.................................................................................................................................................................................1215 Installation............................................................................................................................................................................1215 SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500).......................................................................................................................................1217 Removal.................................................................................................................................................................................1217 Installation............................................................................................................................................................................1217 OPERATOR SEAT (OPTIONAL SEAT)...........................................................................................................................................................1219 Seat Belts..........................................................................................................................................................................1219 Adjustment..........................................................................................................................................................................1219 PASSENGER SEAT (OPTIONAL SEAT)..........................................................................................................................................................1220 Seat Belts..........................................................................................................................................................................1220 Adjustment..........................................................................................................................................................................1220 SEAT BELT REPLACEMENT (OPTIONAL SEATS)......................................................................................................................................................1221 General.................................................................................................................................................................................1221 Removal.................................................................................................................................................................................1221 SECTION N4 HEATER / AIR CONDITIONER INDEX.......................................................................................................................................................1225 HEATER/AIR CONDITIONER..........................................................................................................................................................................1227 OPERATION...................................................................................................................................................................................1227 Fan Speed Control Knob..................................................................................................................................................................1227 Temperature Control Knob................................................................................................................................................................1227 Air Flow Directional Knob...............................................................................................................................................................1228 Heater/Air Conditioner Vents............................................................................................................................................................1228 COMPONENTS..................................................................................................................................................................................1228 Fuse and Circuit Breaker................................................................................................................................................................1228 Relays..................................................................................................................................................................................1228 Heater Core.............................................................................................................................................................................1229 Fan Motor And Speed Control.............................................................................................................................................................1229 Actuators...............................................................................................................................................................................1229 Cab Air Filter..........................................................................................................................................................................1229 ENVIRONMENTAL IMPACT OF AIR CONDITIONING....................................................................................................................................................1232 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...................................................................................................................................................1232 PRINCIPLES OF REFRIGERATION.................................................................................................................................................................1232 Air Conditioning........................................................................................................................................................................1232 Refrigeration - The Act Of Cooling......................................................................................................................................................1233 The Refrigeration Cycle.................................................................................................................................................................1233 AIR CONDITIONER SYSTEM COMPONENTS...........................................................................................................................................................1234 Compressor (Refrigerant Pump)...........................................................................................................................................................1234 Service Valves..........................................................................................................................................................................1234 Condenser...............................................................................................................................................................................1234 Receiver-Drier..........................................................................................................................................................................1234 Expansion Block Valve...................................................................................................................................................................1235 Accumulator.............................................................................................................................................................................1235 Evaporator..............................................................................................................................................................................1235 ELECTRICAL CIRCUIT..........................................................................................................................................................................1236 Thermostat..............................................................................................................................................................................1236 Compressor Clutch.......................................................................................................................................................................1236 Trinary™ Switch.........................................................................................................................................................................1237 AIR CONDITIONING SYSTEM SERVICING WARNINGS..................................................................................................................................................1238 SERVICE TOOLS AND EQUIPMENT.................................................................................................................................................................1239 Recovery/Recycle Station................................................................................................................................................................1239 Leak Detector...........................................................................................................................................................................1239 Service Valves..........................................................................................................................................................................1240 Vacuum Pump.............................................................................................................................................................................1240 Manifold Gauge Set......................................................................................................................................................................1241 Installing Manifold Gauge Set...........................................................................................................................................................1242 Purging Air From Service Hoses..........................................................................................................................................................1242 SYSTEM PERFORMANCE TEST.....................................................................................................................................................................1243 SYSTEM OIL..................................................................................................................................................................................1244 Handling and Reusing PAG Oil............................................................................................................................................................1244 Oil Quantity............................................................................................................................................................................1244 Checking System Oil.....................................................................................................................................................................1244 REFRIGERANT.................................................................................................................................................................................1245 Recycled Refrigerant....................................................................................................................................................................1245 Reclaimed Refrigerant...................................................................................................................................................................1245 Refrigerant Quantity....................................................................................................................................................................1246 R-134a Refrigerant Containers...........................................................................................................................................................1246 SYSTEM LEAK TESTING.........................................................................................................................................................................1246 Electronic Leak Detector................................................................................................................................................................1247 Tracer Dyes.............................................................................................................................................................................1247 Soap and Water..........................................................................................................................................................................1247 RECOVERING AND RECYCLING THE REFRIGERANT....................................................................................................................................................1247 Draining Oil from the Previous Recovery Cycle...........................................................................................................................................1247 Performing the Recovery Cycle...........................................................................................................................................................1247 Performing the Recycling Procedure......................................................................................................................................................1248 Evacuating and Charging the A/C System..................................................................................................................................................1248 SYSTEM REPAIR...............................................................................................................................................................................1248 System Flushing.........................................................................................................................................................................1248 COMPONENT REPLACEMENT.......................................................................................................................................................................1249 Hoses and Fittings......................................................................................................................................................................1249 Lines...................................................................................................................................................................................1249 Expansion Valve.........................................................................................................................................................................1249 Receiver-Drier..........................................................................................................................................................................1249 Thermostat..............................................................................................................................................................................1249 Compressor..............................................................................................................................................................................1250 Accumulator.............................................................................................................................................................................1250 Clutch..................................................................................................................................................................................1250 EVACUATING THE SYSTEM.......................................................................................................................................................................1251 CHARGING THE A/C SYSTEM.....................................................................................................................................................................1252 TROUBLESHOOTING.............................................................................................................................................................................1253 Preliminary Checks......................................................................................................................................................................1253 Diagnosis Of Gauge Readings And System Performance......................................................................................................................................1253 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS..................................................................................................................................................1254 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................................................................................................................................1260 SECTION N5 OPERATOR CAB CONTROLS INDEX..........................................................................................................................................................1261 OPERATOR CAB AND CONTROLS.......................................................................................................................................................................1265 STEERING COLUMN.............................................................................................................................................................................1266 Removal.................................................................................................................................................................................1266 Inspection..............................................................................................................................................................................1266 Installation............................................................................................................................................................................1267 STEERING WHEEL..............................................................................................................................................................................1267 Removal.................................................................................................................................................................................1267 Installation............................................................................................................................................................................1267 STEERING WHEEL AND CONTROLS.................................................................................................................................................................1269 Horn Button.............................................................................................................................................................................1269 Tilt / Telescope Lever..................................................................................................................................................................1269 Multi-Function Turn Signal Switch.......................................................................................................................................................1269 DYNAMIC RETARDING...........................................................................................................................................................................1270 Retarder Lever..........................................................................................................................................................................1270 Brake/Retarder Pedal....................................................................................................................................................................1270 Throttle/Accelerator Pedal..............................................................................................................................................................1270 GRADE/SPEED CHART...........................................................................................................................................................................1271 OVERHEAD PANEL AND DISPLAYS.................................................................................................................................................................1272 CENTER CONSOLE..............................................................................................................................................................................1273 Directional Control Lever...............................................................................................................................................................1273 Override/Fault Reset Switch.............................................................................................................................................................1274 Engine Stop Switch......................................................................................................................................................................1274 L.H. Window Control Switch..............................................................................................................................................................1274 R.H. Window Control Switch..............................................................................................................................................................1274 Hoist Control Lever.....................................................................................................................................................................1274 Raising The Dump Body...................................................................................................................................................................1274 Lowering The Dump Body..................................................................................................................................................................1274 Retard Speed Control (RSC) Adjust Dial..................................................................................................................................................1275 Retard Speed Control (RSC) Switch.......................................................................................................................................................1275 Data Store Button.......................................................................................................................................................................1276 12V Auxiliary Power Outlets.............................................................................................................................................................1276 Fire Suppression Control Outlet.........................................................................................................................................................1276 Communication Radio Outlet..............................................................................................................................................................1276 KOMTRAX Plus Diagnostic Port............................................................................................................................................................1276 Interface Module (IM) Diagnostic Port...................................................................................................................................................1276 Payload Meter Diagnostic Port...........................................................................................................................................................1276 Drive System Or Modular Mining..........................................................................................................................................................1276 Drive System Controller (DSC) Diagnostic Port...........................................................................................................................................1276 Engine Diagnostic Port (CENSE)..........................................................................................................................................................1276 Engine Diagnostic Port (QUANTUM)........................................................................................................................................................1276 HEATER / AIR CONDITIONER....................................................................................................................................................................1277 Fan Speed Control Knob..................................................................................................................................................................1277 Temperature Control Knob................................................................................................................................................................1277 Air Flow Directional Knob...............................................................................................................................................................1277 Heater/Air Conditioner Vents............................................................................................................................................................1277 INSTRUMENT PANEL............................................................................................................................................................................1278 Control Symbols.........................................................................................................................................................................1278 Cab/Air Conditioner Vents...............................................................................................................................................................1280 Status Indicator Light Panel............................................................................................................................................................1280 Hydraulic Oil Temperature Gauge.........................................................................................................................................................1280 Coolant Temperature Gauge...............................................................................................................................................................1280 Speedometer/Digital Display.............................................................................................................................................................1280 Fuel Level Gauge........................................................................................................................................................................1280 Drive System Temperature Gauge..........................................................................................................................................................1280 Hazard Warning Light Switch.............................................................................................................................................................1280 Pre-Shift Brake Test Switch.............................................................................................................................................................1281 Wheel Brake Lock Control................................................................................................................................................................1281 Rest Switch.............................................................................................................................................................................1281 Engine Warm Up Switch (Optional)........................................................................................................................................................1282 Heated Mirror Switch (Optional).........................................................................................................................................................1282 Rotating Beacon Light Switch (Optional).................................................................................................................................................1282 Camera System Switch (Optional).........................................................................................................................................................1282 Key Switch..............................................................................................................................................................................1282 Starting................................................................................................................................................................................1282 Warning Light...........................................................................................................................................................................1283 Digital Display Contrast Buttons........................................................................................................................................................1283 Turn Signal Indicators..................................................................................................................................................................1283 Panel Light Dimmer......................................................................................................................................................................1283 Mode Switches...........................................................................................................................................................................1283 Fog Light Switch (Optional).............................................................................................................................................................1283 Manual Backup Switch....................................................................................................................................................................1284 Headlight/Panel Illumination Light Switch...............................................................................................................................................1284 STATUS INDICATOR LIGHT PANEL................................................................................................................................................................1285 Status Indicator Light Panel............................................................................................................................................................1285 REAR AXLE LIGHT BAR.........................................................................................................................................................................1288 Backup Lights...........................................................................................................................................................................1288 Retard Lights...........................................................................................................................................................................1288 Brake Lights............................................................................................................................................................................1288 Backup Alarm............................................................................................................................................................................1288 DIGIT DISPLAY OPERATION.....................................................................................................................................................................1289 Toggling Through Main Level Screens.....................................................................................................................................................1289 Toggling Through Warning Screens........................................................................................................................................................1290 Entering Payload Meter Data.............................................................................................................................................................1291 KOMTRAX PLUS................................................................................................................................................................................1292 Operation...............................................................................................................................................................................1292 Interface Module........................................................................................................................................................................1294 Basic Precautions.......................................................................................................................................................................1294 KOMATSU WIRELESS BRIDGE (Optional)..........................................................................................................................................................1295 General Information.....................................................................................................................................................................1295 Communication Setup.....................................................................................................................................................................1295 Switching to the KWB_SETUP Network......................................................................................................................................................1295 Setting the Computer Subnet Mask and IP Address.........................................................................................................................................1296 Properties..............................................................................................................................................................................1296 Setting Up the KWB......................................................................................................................................................................1297 Adding Encryption.......................................................................................................................................................................1297 Final Computer Settings.................................................................................................................................................................1297 Data Downloading........................................................................................................................................................................1298 Resetting the KWB.......................................................................................................................................................................1298 KWB Lights..............................................................................................................................................................................1298 SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX............................................................................................................................................1299 SECTION P2 LUBRICATION AND SERVICE INDEX........................................................................................................................................................1301 LUBRICATION AND SERVICE.........................................................................................................................................................................1303 GENERAL.....................................................................................................................................................................................1303 SERVICE CAPACITIES..........................................................................................................................................................................1303 HYDRAULIC TANK SERVICE......................................................................................................................................................................1303 Adding Oil..............................................................................................................................................................................1303 COOLING SYSTEM SERVICE......................................................................................................................................................................1304 Radiator Filling Procedure..............................................................................................................................................................1304 Coolant Specifications..................................................................................................................................................................1304 Unacceptable Practices..................................................................................................................................................................1304 WHEEL MOTOR SERVICE.........................................................................................................................................................................1304 RESERVE OIL TANK SERVICE....................................................................................................................................................................1305 Filling the Reserve Oil Tank (Remote Fill)..............................................................................................................................................1305 Inline Screen...........................................................................................................................................................................1305 QUICK FILL SERVICE CENTER...................................................................................................................................................................1306 LUBRICATION CHART...........................................................................................................................................................................1307 10 HOUR (DAILY) INSPECTIONS.................................................................................................................................................................1308 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................................................................................................................................1311 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................................................................................................1311 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................................................................................................1311 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................................................................................................1314 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................................................................................1316 5000 HOUR MAINTENANCE CHECKS................................................................................................................................................................1316 INJECTOR OPERATION......................................................................................................................................................................1326 SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX...................................................................................................................................................1317 AUTOMATIC LUBRICATION SYSTEM....................................................................................................................................................................1319 GENERAL DESCRIPTION.........................................................................................................................................................................1319 SYSTEM COMPONENTS...........................................................................................................................................................................1321 Filter..................................................................................................................................................................................1321 Hydraulic Motor and Pump................................................................................................................................................................1321 Grease Reservoir........................................................................................................................................................................1321 Pressure Reducing Valve.................................................................................................................................................................1321 Flow Control Valve......................................................................................................................................................................1321 Solenoid Valve..........................................................................................................................................................................1321 Vent Valve..............................................................................................................................................................................1321 Over Pressure Cut Off Switch............................................................................................................................................................1321 Grease Pressure Failure Switch..........................................................................................................................................................1321 Injectors...............................................................................................................................................................................1321 Interface Module........................................................................................................................................................................1321 Relief Valve (unloader valve)...........................................................................................................................................................1321 SYSTEM OPERATION............................................................................................................................................................................1322 Normal Operation........................................................................................................................................................................1322 Lubricant Required For System...........................................................................................................................................................1323 Filter Assembly.........................................................................................................................................................................1323 LUBRICANT PUMP..............................................................................................................................................................................1324 Pump Housing Oil Level..................................................................................................................................................................1324 Pump Pressure Control...................................................................................................................................................................1324 INJECTORS (SL-1 Series “H”).................................................................................................................................................................1325 Injector Specifications.................................................................................................................................................................1325 Injector Adjustment.....................................................................................................................................................................1325 PREVENTIVE MAINTENANCE PROCEDURES...........................................................................................................................................................1327 Daily Lubrication System Inspection.....................................................................................................................................................1327 250 Hour Inspection.....................................................................................................................................................................1327 1000 Hour Inspection....................................................................................................................................................................1327 SYSTEM CHECKOUT.............................................................................................................................................................................1328 Lubrication Cycle Operation.............................................................................................................................................................1328 SYSTEM TROUBLESHOOTING CHART....................................................................................................................................................................1329 SECTION R SYSTEM SCHEMATICS INDEX...............................................................................................................................................................1331 CEBM028100_cov.pdf.............................................................................................................................................................................. 0 CEBM028100.................................................................................................................................................................................. 1 930E-4...................................................................................................................................................................................... 1 DUMP TRUCK.............................................................................................................................................................................. 1
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